CHRYSLER CUSW FANUC Robot Standard Rev1 1

Chrysler’s
Robotics Group Applications Standards For
Controlled Robots For Use On

CUSW North America Projects
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AS OF 2/4/2011 1 CUSW REL1.1

Printed copies are not source controlled
TABLE OF CONTENTS
RELEASE REVISION AND COMMENTS PAGE...................................................................................................... 4
PROCESS REQUIREMENTS TO ALLOW FOR ALIGNMENT OF ROBOT ............................................................ 6
ROBOTIC BY-PASS CONCEPT ............................................................................................................................... 6
TEACH PENDANT USER KEY ASSIGNMENT ........................................................................................................ 6
USE OF PULSED OUTPUTS .................................................................................................................................... 6
USE OF ROBOT PROGRAM SPACE CHECK ........................................................................................................ 6
COORDINATED MOTION OF HORIZONTAL AXIS ................................................................................................. 6
ROBOT DRESS REQUIREMENTS........................................................................................................................... 6
FANUC ROBOTICS ROBOT SIGNALS AND MACHINE AUTOMATIC .................................................................. 7
ROBOT D-NET OUTPUT BIT MAP (ROBOT TO PLC)............................................................................................ 8
ROBOT D-NET INPUT BIT MAP (PLC TO ROBOT).............................................................................................. 12
ROBOT IO MAP ASSIGNMENTS ........................................................................................................................... 16
ROBOT BIT MAP .................................................................................................................................................... 17
ROBOT APPLICATION ERROR TIMING ............................................................................................................... 36
ROBOT APPLICATION ERRORS .......................................................................................................................... 37
PLC LOGIC REFERENCE ...................................................................................................................................... 43
ROBOT PROGRAM NAMING ................................................................................................................................. 44
ROBOT INTERFERENCE ZONES.......................................................................................................................... 45

INTERFERENCE ZONE EXAMPLE 1 ............................................................................................................................ 46
INTERFERENCE ZONE EXAMPLE 2 ............................................................................................................................ 47
PLC / ROBOT TIMING DIAGRAMS........................................................................................................................ 48
REGISTER USAGE ................................................................................................................................................. 51
NUMERICAL REGISTER USAGE .......................................................................................................................... 51
POSITION REGISTER USAGE ............................................................................................................................... 53
USER ALARMS ....................................................................................................................................................... 55
REFERENCE POSITION USAGE ........................................................................................................................... 56
INTERCONNECTS .................................................................................................................................................. 57
MACROS ................................................................................................................................................................. 58
FLOW CHART EXAMPLES .................................................................................................................................... 60

MATERIAL HANDLING .............................................................................................................................................. 61
DISPENSE............................................................................................................................................................... 66
SPOT W ELDING ...................................................................................................................................................... 67
AS OF 2/4/2011 2 CUSW REL1.1

STUD W ELDING ...................................................................................................................................................... 69
TIP CHANGE (STYLE #3) ......................................................................................................................................... 70
PURGE (STYLE #4) ................................................................................................................................................. 71
TIP BURN IN (STYLE #5).......................................................................................................................................... 72
SERVICE (STYLE #6) ............................................................................................................................................... 73
TIP DRESS GUN 1 (STYLE #7) ................................................................................................................................. 74
TIP DRESS GUN 2 (STYLE #8) ................................................................................................................................. 75
TOOL CHANGE (STYLE #9) ...................................................................................................................................... 76
SET APPLICATION IO (MACRO) ................................................................................................................................ 77
CHECK ATI ERRORS (MACRO) ................................................................................................................................ 78
CHECK TOOL (MACRO) ........................................................................................................................................... 79
DROP TOOL NEST 1 (MACRO) ................................................................................................................................. 80
ENTER ZONE 1 (MACRO)......................................................................................................................................... 82
HOME IO (MACRO) ................................................................................................................................................. 82
MOVE HOME (MACRO) ............................................................................................................................................ 82
MOVE HOME FROM POUNCE (MACRO) .................................................................................................................... 82
PICK TOOL NEST 1 (MACRO) ................................................................................................................................... 83
PROCESS APPLICATION MACROS (SPOT, DISPENSE, STUD) ...................................................................................... 85
PURGE PED GUN (MACRO) ..................................................................................................................................... 88
RESET STEPPER (MACRO) ...................................................................................................................................... 88
TIP BURN IN (MACRO) ............................................................................................................................................. 89
TIP DRESS GUN 1 (MACRO) .................................................................................................................................... 91
TIP DRESS GUN 2 (MACRO) .................................................................................................................................... 92
TIP DRESS PED GUN (MACRO) ................................................................................................................................ 93
TOOL DROP PREPARATION (MACRO) ....................................................................................................................... 94
TOOL PICK PREPARATION (MACRO)......................................................................................................................... 95
TEACH PENDANT LOGIC EXAMPLES ................................................................................................................. 96
MATERIAL HANDLING .............................................................................................................................................. 97
DISPENSE............................................................................................................................................................... 99
SPOT W ELDING .................................................................................................................................................... 100
STUD W ELDING .................................................................................................................................................... 101
TIP CHANGE (STYLE #3) ....................................................................................................................................... 102
PURGE (STYLE #4) ............................................................................................................................................... 102
TIP BURN IN (STYLE #5)........................................................................................................................................ 103
SERVICE PROGRAM (STYLE #6)............................................................................................................................. 103
TIP DRESS GUN 1 (STYLE #7) ............................................................................................................................... 103
TIP DRESS GUN 2 (STYLE #8) ............................................................................................................................... 104
TOOL CHANGE (STYLE #9) .................................................................................................................................... 104
CHECK ATI ERRORS (MACRO) .............................................................................................................................. 105
CHECK TOOL (MACRO) ......................................................................................................................................... 106
DROP TOOL NEST 1 (MACRO) ............................................................................................................................... 107
PICK TOOL NEST 1 (MACRO) ................................................................................................................................. 108
ENTER ZONE 1 (MACRO)....................................................................................................................................... 110
HOME IO (MACRO) ............................................................................................................................................... 110
PROCESS APPLICATION – PED SPOT (MACRO) ....................................................................................................... 111
PROCESS APPLICATION – PED DISPENSE (MACRO) ................................................................................................ 112
PROCESS APPLICATION – PED STUD (MACRO) ....................................................................................................... 113
PURGE PED GUN (MACRO) ................................................................................................................................... 113
RESET STEPPER (MACRO) .................................................................................................................................... 113
TIP BURN IN (MACRO) ........................................................................................................................................... 113
TIP CHANGE PED GUN (MACRO) ........................................................................................................................... 113
TIP DRESS GUN 1 (MACRO) .................................................................................................................................. 115
TIP DRESS GUN 2 (MACRO) .................................................................................................................................. 115
TIP DRESS PED GUN (MACRO) .............................................................................................................................. 116
TOOL DROP PREPERATION (MACRO) ..................................................................................................................... 117
TOOL PICK PREPERATION (MACRO)....................................................................................................................... 118
The flow charts and sample programs supplied in this document are intended as a basic example and may not include all information required
to properly control a robot in all applications. It is the build vendor's responsibility to provide robot programming required for proper system
operation. The examples set forth in this document shall be followed. Any deviations will require approval by Chrysler Robot Specialist.
AS OF 2/4/2011 3 CUSW REL1.1

RELEASE REVISION AND COMMENTS PAGE
Release # Release Date Comments
Rel. 1.0 12/14/10 - Initial Release
Rel. 1.1 2/4/11 Adjusted Rbt/PLC bitmap to eliminate water saver control. DO[99], DI[7], DI[97], DI[98].
Update the Node Allocation – Eliminated the Water Savers, moved to PLC control.
Updated Rbt/PLC Node descriptors per the bitmap.
Spared out 4 Water Saver Nodes-I/O.
Updated Safety I/O
Added WaterOff to the bitmap DO[100]
Removed reference to WK and WD in robot program naming
Spared out DO91, 92, 95, 96 and 100 – Use Group Output [MaintReqBits1-8].
(TipChangeReq, ServiceReq, RbtTPPurgeGun1, RbtTPPurgeGun2, TipDressReq)
Added air pressure master node and outputs to PLC DO[91] and [92]
Added StepMode output DO[103]
Added SignatureChgInd output DO[111]
Updated Watersaver App Errors
Updated Nordson App Errors to match new configuration
Updated Nordson BitMap to match new configuration
AS OF 2/4/2011 4 CUSW REL1.1

AS OF 2/4/2011 5 CUSW REL1.1
PROCESS REQUIREMENTS TO ALLOW FOR ALIGNMENT OF
ROBOT
It is an AAME requirement that all Body shop and Assembly robots be capable of running an alignment program. This program will bring the
robot into a position which will allow positioning of all axes to check robot alignment. The robot alignment position and path to reach this
position must be considered when locating and processing the robot in the cell. Consideration must also be given when dressing out robot
cables, hoses, end effectors and junction boxes on the robot arm so these items do not impede the robots ability to move to the alignment
position. Where possible, all axes should be aligned at the same time. In cases where cell layout would be affected or additional dress-out or
safeties would be required to align all axes simultaneously, multiple alignment positions will be allowed. In addition to alignment program, all
OEM‟S must verify that the robot is set to FANUC ROBOTICS factory values for alignment position prior to programming robot.
PROCESS CYCLE TIME REQUIREMENTS

It is an AAME requirement that all Body shop and Assembly robots be capable of meeting
process cycle time without the presence of robot errors or warnings of any kind.
ROBOTIC BY-PASS CONCEPT

The Robot By-pass Mode is selected through the HMI screen associated with the specific robot.
When in By-pass Mode, the PLC logic should allow the following:
In processes which allow a specific robot to be by-passed, (line capable of running without this specific robot with manual or automatic back-
up capabilities).
A. Allow the current part or job to transfer out of that station (if the robot is clear).
B. Allow the line to continue to run while the robot is in by-pass and clear of all tooling.
C. Send required back-up information to down stream robot(s) and/or FIS/AVI for downstream manual backup.
In processes which do not allow for the line to run with a specific robot in by-pass.
A. Allow the current part or job to transfer out of that station (if the robot is clear).
B. Stop further machine cycles if left in by-pass mode.
C. Allow for easy changes to the PLC logic to override item “B” in the event that the plant provides temporary manual back-up for
continued production.
Note: Process Engineering, during the Design Phase of a project, will identify robots that can be
by-passed while tooling continues to operate.
TEACH PENDANT USER KEY ASSIGNMENT

The user definable keys on the robot teach pendants are to remain at FANUC ROBOTICS default settings unless a deviation is submitted by
the Requestor and approved by a Chrysler Robotic Group representative.
USE OF PULSED OUTPUTS

The use of pulsed outputs requires approval by a Chrysler Robot Specialist.
USE OF ROBOT PROGRAM SPACE CHECK

The use of robot program space check requires approval by a Chrysler Robot Specialist.
COORDINATED MOTION OF HORIZONTAL AXIS

All robots utilizing a horizontal slide axis shall be setup and programmed using coordinated motion with the other six axes of the robot arm.
ROBOT DRESS REQUIREMENTS

FANUC robot dress packages for all spot welding and material handling robots will be supplied for installation. It is the responsibility of the
build supplier (robot programmer) to adjust and validate all robot dress packages to meet the dress manufacturer‟s warranty. Robot programs
must be considered when configuring the supplied dress package.
AS OF 2/4/2011 6 CUSW REL1.1

FANUC ROBOTICS ROBOT SIGNALS AND MACHINE AUTOMATIC
The PLC logic should monitor the following robot DeviceNet outputs. The “Robot Ready” signal should be true to achieve machine automatic
but is not required to maintain machine automatic. Proper fault messages should be generated for each associated condition.
“Robot Ready” DeviceNet - This signal is true when the following conditions are met:
CMDENBL SI[2]=ON (OK) (standard operator panel input 2, remote)

CMDENBL SFSPD=ON (OK) (safety speed input signal)
CMDENBL ENBL=ON (OK)
CMDENBL $RMT_MASTER=0 (OK) (no remote device in control of motion)
CMDENBL No active alarms (OK)
CMDENBL Not in single step (OK)
SYSRDY ENBL=ON (OK)
SYSRDY GRP1 Servo ready (OK)
SYSRDY GRP2 Servo ready (OK) (Spotweld only)
GRP1 Motion enabled (OK) (Robot motion group)
GRP2 Motion enabled (OK) (Servo motion group, spotweld only)
Spot weld enabled (OK) (Weld status, welding applications only)
Gun stroke enabled (OK) (Gun stroke status, welding applications only)
The following signals are available through DeviceNet and should be displayed as faults or messages when their appropriate state hinders
achievement of the tooling system automatic:
Robot System Ready for AUTO

RobotInAuto
RbtReady
IOSimulated
20HourRunModeAct
Collision Guard Enabled
TP Enabled
Waiting for TP Input
Robot E-Stop Enabled
Weld Enabled (Spotweld only)
STEP Mode
AS OF 2/4/2011 7 CUSW REL1.1

ROBOT D-NET OUTPUT BIT MAP (ROBOT TO PLC)
SIGNAL NAME ROBOT OUTPUT DESCRIPTION
RobotInAuto 1 This robot output signal is used to inform the PLC that the robot Auto/Teach key
switch is the auto position.
RobotFaulted 2 This robot output signal is used to inform the PLC that the robot is in a faulted state.
WaitForTPInput 3 This robot output signal is used to inform the PLC that a user response is required at
the robot teach pendant.
InCycle 4 This robot output signal is used to inform the PLC that a robot program is executing.
This includes Home I/O execution. “InCycle” remains high when the program is
paused.
CollisionDetd 5 This robot output signal is used to inform the PLC that a collision was detected on
the robot.
IOSimulated 6 This robot output signal is used to inform the PLC that a robot input is simulated.
WldEnabled 7 This robot output signal is used to inform the PLC that the weld mode is enabled at
the weld controller.
RobotReady 8 This robot output signal is used to inform the PLC that all conditions for robot ready
are satisfied.
ActiveStyleBit1 9 This robot output along with the next six bits, grouped as “Group Outputs”, are used
to inform the PLC of the current style active. The group outputs are viewed as the
binary bit weight viewed as a decimal value.
ActiveStyleBit2 10 Reference description: “ActiveStyleBit1”
PrgPaused 16 This robot system output signal “UO[4: Paused]” is used to inform the PLC that the
robot program is in a paused condition. Signal is active in Auto and Teach modes.
PrgRunning 17 This robot system output signal “UO[3: Program Running]” is used to inform the
PLC that the robot program is running. Signal is active in Auto and Teach modes.
RobotAtWork 18 This robot output signal is used to inform the PLC that the robot has left the pounce
position and is in the work portion of the robot program.
WorkComplete 19 This robot output signal is used to inform the PLC that the robot has completed the
work program. Resets after WorkCompleteAck received from the PLC.
20HourRunModeAct 20 This robot output signal is used to inform the PLC that the robot is in 20 hour run
mode.
MaintReqBit1 21 This robot output signal along with the next 3 bits, grouped as “Group Outputs” are
used to inform the PLC to execute the desired maintenance program 1-9. The group
outputs are viewed as the binary bit weight viewed as a decimal value.
MaintReqBit2 22 Reference description: “MaintReqBit1”
RobotAtPounce 25 This robot output signal is used to inform the PLC that the robot is at the pounce
position. (Output set by user program)
RobotAtService 26 This robot output signal is used to inform the PLC that the robot is at the service
position.
RobotAtHome 27 This robot output signal is used to inform the PLC that the robot is at the home
position.
RobotInTipDress 28 This robot output signal is used to inform the PLC that the robot is at the tip dress
position.
TipDressComplt 29 This robot output signal is used to inform the PLC that the tip dress procedure has
completed.
RdyForTipChg 30 This robot output signal is used to inform the PLC that the robot is in tip change
position.
ClearToTransfer 31 This robot output signal is used to inform the PLC that the robot is clear of the
transfer.
WldInPrgrsActiv1 32 This robot output signal is used to inform the PLC that the weld controller 1 is
executing a weld sequence.
AS OF 2/4/2011 8 CUSW REL1.1

RobotClrZone1 33 This robot output signal is used to inform the PLC that the robot is clear of
interference zone 1.
interference zone 2
UserOutput1 41 This robot output signal is designated as user defined output 1.
ClrOfPickup1 49 This robot output signal is used to inform the PLC that the robot is clear of pickup 1
position.
AtPickup1 50 This robot output signal is used to inform the PLC that the robot is at the pickup 1
position.
ClrOfDropoff1 51 This robot output signal is used to inform the PLC that the robot is clear of dropoff 1
position.
AtDropoff1 52 This robot output signal is used to inform the PLC that the robot is at the dropoff 1
position.
position.
position.
position.
position.
position.
position.
position.
position.
position.
position.
position.
position.
Clr2UnclampEarly 65 This robot output signal is used to inform the PLC that the robot is clear to unclamp
the tooling.
RbtAtUserPos1 66 This robot output signal is used to inform the PLC that the robot is at user position 1
AS OF 2/4/2011 9 CUSW REL1.1
Spare 70 Spare
Req2EntrToolNest 71 This robot output signal is used as a request from the robot, entry to the tool nests to
the PLC.
ClearOfToolNest 72 This robot output signal is used to inform the PLC that the robot is clear of the tool
nest.
ServiceComp 73 This robot output signal is used to signal the PLC that service is complete.
MajorMinorFlt 74 This robot output signal is used to signal the PLC that the posted application error is
a major fault
WaitingForPlcCmd 75 This robot output signal is used to inform the PLC that the robot is waiting for a PLC
command. (Active while in a user program – WaitDI or WaitGI)
RemoveFault 76 This robot output signal is used to inform the PLC to remove the application error.
RobotPartPres1 77 This robot output signal is used to inform the PLC that part present 1 is activated.
Spare 87 Spare
Spare 88 Spare
PickOverride 89 This robot output signal is used to inform the PLC that the robot is in a pick over ride
process.
CollisGuardEnbld 90 This robot output signal is used to inform the PLC if collision guard is enabled.
AirPressAcptRng 91 This robot output indicates the air pressure is within acceptable range.
AIr OK 92 This robot output indicates the air pressure is OK
WetDryMode 93 This robot output signal is used to inform the PLC if the robot is in Wet mode.
AbortPickReq 94 This robot output signal is used to inform the PLC that the robot is requesting the
abort pick sequence.
Spare 95 Spare
Spare 96 Spare
ExtPurg1InProgrs 97 This robot output signal is used to inform the PLC that dispenser 1 purge sequence
is in progress.
ExtPurg2InProgrs 98 This robot output signal is used to inform the PLC that dispenser 2 purge sequence
is in progress.
WaterOn 99 This robot output signal is used to inform the PLC to turn the water saver on.
WaterOff 100 This robot output signal is used to inform the PLC to turn the water saver off.
TurnOnTipDresser 101 This robot output signal is used to inform the PLC to turn on the tip dresser motor(s).
StepperResetAck 102 This robot output signal is used to inform the PLC that the weld controller has reset
stepper .
StepMode 103 This robot output signal is used to inform the PLC that the robot is in StepMode.
RobotAtPurgePos 104 This robot output indicates the robot is in position to purge.
RobotClrFixt1 105 This robot output signal is used to inform the PLC that the robot is clear of fixture 1
(based on automatic zone/window definition in the robot).
RobotClrFixt2 106 This robot output signal is used to inform the PLC that the robot is clear of fixture 2
(based on automatic zone/window definition in the robot).
Spare 107 Spare
Spare 108 Spare
ReposTooling1 109 This robot output along with the next two bits, (ReposTooling2 – ReposTooling4)
grouped as “Group Outputs”, are used to inform the PLC to reposition the tooling.
The group outputs are viewed as the binary bit weight viewed as a decimal value.
ReposTooling2 110 Reference description: “ReposTooling1”
SignatureChgInd 111 This robot output indicates to the PLC that the DCS signature current and previous
match and have been verified.
AS OF 2/4/2011 10 CUSW REL1.1

RbtAtInspectPos 112 This robot output signal is used to inform the PLC that the robot is at the inspection
position.
TeachPendantEnbd 113 This robot output signal is used to inform the PLC that the teach pendant switch is
enabled.
StartExtApp1Proc 114 This robot output informs the PLC to start external application 1 process.
StartExtApp2Proc 115 This robot output informs the PLC to start external application 2 process.
ToolIDOnWrist1 116 This robot output signal along with the next two bits, (ToolIDOnWrist2 -
ToolIDOnWrist4) grouped as “Group Outputs”, are used to inform the PLC which tool
is on the robot wrist. The group outputs are viewed as the binary bit weight viewed
as a decimal value.
ToolIDOnWrist2 117 Reference description: “ToolIDOnWrist2”
ToolIDOnWrist4 118 Reference description: “ToolIDOnWrist4”
ProcessFault 119 This robot output signal is used to inform the PLC that a process fault is present.
AppErrorActive 120 This robot output signal is used to inform the PLC that an application error is active.
Reference: Robot input 8 as acknowledge to this bit.
AppErrorBit1 121 This robot output signal along with the next seven bits, (AppErrorBit2 -
AppErrorBit128) grouped as “Group Outputs”, are used to inform the PLC of the
current value of the application error that is posted. The group outputs are viewed
as the binary bit weight viewed as a decimal value.
AppErrorBit2 122 Reference description: “AppErrorBit1”
Reference DCX Book of Implementation Guidelines for proper Tag and UDT Naming – Design standards for Control Logix AMS 0220 Section 9.3.2, 7.0 Tag –
DeviceNet Tag Naming Guidelines, Starting on page 28.
AS OF 2/4/2011 11 CUSW REL1.1

ROBOT D-NET INPUT BIT MAP (PLC TO ROBOT)
SIGNAL NAME ROBOT INPUT # DESCRIPTION
NoHold 1 This robot system input “UI[2:Hold]” is used to decelerate and stop the robot. This
signal is held high for normal operation of the robot.
Resume 2 This robot system input “UI[6:Start]” is used to resume a paused style program.
FaultReset 3 This robot system input “UI[5:Fault Reset]” is used to reset robot and robot
controlled peripheral device faults.
20HourRunMode 4 This robot input is used to put the robot into 20 hour run mode.
ReqToEnter 5 This robot input is used to pause the robot program after it has completed the current
task and/or motion.
Spare 6 This robot input is not currently used.
AppErrorAck 8 This robot input is used as an acknowledgment from the PLC that the application
error has been read.
STYLEBit1 9 This robot system input “UI[9:RSR1/PNS1/STYLE1]” along with the next six bits,
grouped as “Group Inputs”, are used for style selection inputs from the PLC. The
group inputs are viewed as the binary bit weight in a decimal fashion.
STYLEBit2 10 System input “UI[10:RSR2/PNS2/STYLE2]” Reference description: “Style1”
WeldGunForceChk 16 This robot input is used to initiate the weld gun force check from a style program at
the wait for dropoff position.
InterferenceClr1 17 This robot input is used to signal the robot that interference is clear at area 1.
InterferenceClr2 18 This robot input is used to signal the robot that interference is clear at area 2.
AcceptVolume 19 This robot input is used to externally accept the sealer bead from the PLC if a
volume fault was issued.
VolumeFltReset 20 This robot input is used to externally tell the robot from the PLC to reset a volume
fault on the dispense unit.
PPOK_ClrToGrip 21 This robot input is used to signal the robot to grip the part. (Used for Clr to Grip part)
GripOK_ClrToExit 22 This robot input is used to signal the robot to exit the position. (Used for Clmp&Hold)
AbortExitPick 23 This robot input is used to signal the robot to Abort Exit Pick.
AbortExitDrop 24 This robot input is used to signal the robot to Abort Exit Drop.
RetFromPounce 25 This robot input is used to signal the robot to return from the pounce position back to
the home position. When executed, the robot program will return to the home
position and mainline program without issuing a “WorkComplete”.
ServiceCompltReq 26 This robot input is used to signal the robot to complete the service program and
return to home position and mainline program from the service position.
ServiceRequest 27 This robot input is used to signal the robot to execute a maintenance routine when
the robot is at the Waiting for Dropoff# position. (M/H robots only)
TipDressGunReq 28 This robot input is used to signal the robot to initiate the tip dress procedure from a
style program.
ProdStart 29 This robot system input “UI[18:Prod Start]” is used to initiate a new style program.
When this bit is high and a style number has been set, the robot will start executing
the selected style program. [Go to pounce position of selected program]
Spare 30 This robot input is not used.
GoToWork 31 This robot input is used to signal the robot to leave “Pounce Position” and execute
the work portion of the robot program.
WorkCompleteAck 32 This robot input is used to signal that “WorkComplete” was received by the PLC.
Zone1ClrToEnter 33 This robot input is used to inform the robot that interference zone 1 is clear to enter.
Reference the AME zone logic standard for further information.
AS OF 2/4/2011 12 CUSW REL1.1

UserInput1 41 This robot input is designated as a user defined input. If used, the robot program
must be annotated to identify the use of this user input.
GoToPickup1 49 This robot input is used to signal the robot to continue its program to the pickup 1
position.
ExitPickup1 50 This robot input is used to signal the robot to continue its program from the pickup 1
position.
GoToDropoff1 51 This robot input is used to signal the robot to continue its program to the dropoff 1
position.
ExitDropoff1 52 This robot input is used to signal the robot to continue its program from the dropoff 1
position.
position.
position.
position.
position.
position.
position.
position.
position.
position.
position.
position.
position.
Part1InFixture 65 This robot input is used to signal the robot that part 1 is present in the tooling fixture.
AS OF 2/4/2011 13 CUSW REL1.1

App1ClrToEnter 71 This robot input is used to signal the robot that the process application 1 fixture/area
is clear for the robot to enter.
App2ClrToEnter 72 This robot input is used to signal the robot that the process application 2 fixture/area
is clear for the robot to enter.
ToolInNest1 73 This robot input is used to inform the robot there is a tool present in nest 1.
PickTool1 77 This robot input along with the next three bits, (PickTool2 – PickTool8) grouped as
“Group Inputs”, are used to signal the robot to pick up a specific tool. The group
inputs are viewed as the binary bit weight in a decimal fashion.
PickTool2 78 Reference description: “PickTool1”
Clr2EntToolNest 81 This robot input is used to signal the robot that the tool nest(s) is clear to enter.
ToolingRepod1 82 This robot input along with the next two bits, (ToolingRepod2 – ToolingRepod4)
grouped as “Group Inputs”, are used to signal the robot that the tooling/fixture/dumps
are repositioned. The group inputs are viewed as the binary bit weight in a decimal
fashion.
ToolingRepod2 83 Reference description: “ToolingRepod1”
ToolingRepod4 84 Reference description: “ToolingRepod1”
PalletPosBit1 85 This robot input along with the next seven bits, (PalletPosBit2 – PalletPosBit128)
grouped as “Group Inputs”, are used to signal the robot to move to a specific pallet
position.
PalletPosBit2 86 Reference description: “PalletPosBit1”
WetDryMode 93 This robot input is used to signal the robot to go into Wet mode.
AbortReq 94 This robot input is used to signal the robot to run an Abort routine.
PurgeGun1Req 95 This robot input is used to signal the robot to execute a purge sequence for
dispenser 1.
PurgeGun2Req 96 This robot input is used to signal the robot to execute a purge sequence for
dispenser 2.
WaterFlowOK 97 This robot input is used to signal the robot that water flow is OK.
TipDressDumpExtd 99 This robot input is used to signal the robot that the tip dresser dump is extended.
TipDrsDumpRetrct 100 This robot input is used to signal the robot that the tip dresser dump is retracted.
TipDrsMotorOn 101 This robot input is used to signal the robot that the tip dresser motor is running.
ExtStepperReset1 102 This robot input is used to signal the robot to reset weld controller stepper 1.
ExtStepperReset2 103 This robot input is used to signal the robot to reset weld controller stepper 2.
TipBurnInReq 104 This robot input is used to call the tip burn in program from the work program while
the robot is at home position and from the wait for dropoff position. (Requires input
looping)
TipChgReq 105 This robot input is used to call the tip change program from the work program while
the robot is at home position and from the wait for dropoff position. (Requires input
looping)
InspectRequired 106 This robot input is used to signal the robot to execute the inspection process.
InspectComplete 107 This robot input is used to signal the robot to return from inspection position.
ClrToExitUsrPos1 108 This robot input is used to signal the robot that it is clear to exit user position 1.
AS OF 2/4/2011 14 CUSW REL1.1

ExtApp1StartReq 113 This robot input is used to signal the robot to tell dispense controller 1 to initiate a
remote start.
ExtApp1Complete 114 This robot input is used to signal the robot that external application 1 is complete.
ExtApp2StartReq 115 This robot input is used to signal the robot to tell dispense controller 2 to initiate a
remote start.
ExtApp2Complete 116 This robot input is used to signal the robot that external application 2 is complete.
Reseal 117 This robot input is used to execute a Reseal process.
RejectPart 118 This robot input is used to execute a Reject Part process
NoSafeSpeed1 119 This robot input is used to drop the robot into a slow speed during part inspection.
ReweldStud 120 This robot input is used to command the robot to issue a Reweld Stud command.
(Fault Ack and Start1 or Start2 to ST/W.
AcceptStud 121 This robot input is used to command the robot to issue a Accept Stud command.
(Fault Ack to ST/W and Weld Complete to robot)
RejectStud 122 This robot input is used to command the robot to issue a Reject Stud command.
(Fault Ack to ST/W and Weld Complete and JumpLbl to Dropoff to the robot.
ChangedHead 123 This robot input is used to instruct the robot that the ST/W head has been changed.
StudSlide1InPos 124 This robot input indicates to the robot, that studwelder 1 is in the weld position.
StudSlide2InPos 125 This robot input indicates to the robot, that studwelder 2 is in the weld position.
PickOverrideReq 126 This robot input indicates to the robot to execute the pick override section of the
program
ReservedPLCdi127 127 This robot input is not currently used.
NoSafeSpeed2 128 This robot input is used to drop the robot into a slow speed during part inspection.
Reference DCX Book of Implementation Guidelines for proper Tag and UDT Naming – Design standards for Control Logix AMS 0220 Section 9.3.2, 7.0 Tag –
DeviceNet Tag Naming Guidelines, Starting on page 28.
ROBOT OUTPUTS ROBOT INPUTS

SAFETY PLC COMMUNICATIONS SAFETY PLC COMMUNICATIONS
NODE ROBOT NODE ROBOT
ADDRESS ADDRESS SIGNAL NAME ADDRESS ADDRESS SIGNAL NAME
1 CSO 1 ESPB 1 CSI 1 EES
1 CSO 2 RB MTR OFF 1 CSI 2 EGS
1 CSO 3 AUTO 1 CSI 3 SW24V
1 CSO 4 AXP1 MON 1 CSI 4 TC24V
1 CSO 5 TC24V MON 1 CSI 5 spare
1 CSO 6 spare 1 CSI 6 spare
1 CSO 7 DM MON 1 CSI 7 spare
1 CSO 8 CSBP 1 CSI 8 spare
1 CSO 10 Joint 1 Zone Disabled 1 CSI 10 Joint 1 Zone Disable
1 CSO 11 Joint 2 Zone Disabled 1 CSI 11 Joint 2 Zone Disable
AS OF 2/4/2011 15 CUSW REL1.1

ROBOT IO MAP ASSIGNMENTS
OUTPUT INPUT
ROBOT COMMUNICATION ASSIGNMENTS ASSIGNMENTS NODE NUMBER
PLC COMMUNICATIONS DO [1 - 128] DI [1 - 128] 1
SPARES DO [129 - 192] DI [129 - 192]
SPOT WELD SCR#1 DO [193 - 224] DI [193 - 224] 11

NELSON STUD WELDER DO [321 - 384] DI [321 - 384] 16
DISPENSE #1 DO [385 - 448] DI [385 - 448] 25

DISPENSE #2 DO [449 - 512] DI [449 - 512] 26
MH EOAT MODULE #1 INPUT DI [513 - 528] 31

MH EOAT MODULE #1 OUTPUT DO [513 - 544] 39

MH EOAT MODULE MISC OUTPUT DO [545 - 576] 36
SPARE DO [577 - 585]
MH EOAT VAC MODULE #1 DO [593 - 600] DI [593 - 600] 37

MH EOAT VAC MODULE #2 DO [601 - 608] DI [601 - 608] 38
USER DEFINABLE IO #1 DO [609 - 616] DI [609 - 616] 43
USER DEFINABLE IO #2 DO [617 - 624] DI [617 - 624] 44
SPARE DO [625 - 631] DI [625 - 631]
ATI TOOLCHANGER DO [632 - 639] DI [632 - 695] 54

ATI TOOLCHANGER (Robot Internal) DO [640 - 654]
SPARES DO [640 - 695]
FORM & PIERCE MOOG DO [696 - 727] DI [696 - 727] 48

FORM & PIERCE CLINCH NUT-FEEDER DO [728 - 743] DI [728 - 743] 49
FORM & PIERCE CLINCH NUT-TOOL DO [744 - 759] DI [744 - 759] 50
FORM & PIERCE PUMP DO [760 - 767] DI [760 - 767] 51
SPARES DO [768 - 784] DI [768 - 784]

TOOLCHANGER COVER / NEST #1 55
SPARES DO [785 - 792] DI [785 - 816] 17

SPARES DO [817 - 824] DI [817 - 848] 18
SPARES DO [849 - 856] DI [849 - 880] 19
SPARES DO [881 - 888] DI [881 - 912] 20
SPARES DO [793 - 816]

SPARES DO [885 - 848]
SPARES DO [857 - 880]
SPARES DO [889 - 912]
ISRA OR OTHER VISION DO [913 - 944] DI [913 - 1024] 60
APP ERROR SPARES DO [945 - 1024]
AS OF 2/4/2011 16 CUSW REL1.1

ROBOT BIT MAP
PLC COMMUNICATIONS PLC COMMUNICATIONS
NODE ROBOT PMC GROUP NODE ROBOT PMC GROUP

ADDRESS ADDRESS ADDRESS ASSIGNMENT SIGNAL NAME ADDRESS ADDRESS ADDRESS ASSIGNMENT SIGNAL NAME
1 DO 1 Y 0.0 RobotInAuto 1 DI 1 X 0.0 NOHold
1 DO 2 Y 0.1 RobotFaulted 1 DI 2 X 0.1 Resume
1 DO 3 Y 0.2 WaitForTPInput 1 DI 3 X 0.2 FaultReset
1 DO 4 Y 0.3 InCycle 1 DI 4 X 0.3 20HourRunMode
1 DO 5 Y 0.4 CollisionDetd 1 DI 5 X 0.4 ReqToEnter
1 DO 6 Y 0.5 IOSimulated 1 DI 6 X 0.5 Spare
1 DO 7 Y 0.6 WldEnabled 1 DI 7 X 0.6 Spare
1 DO 8 Y 0.7 RobotReady 1 DI 8 X 0.7 AppErrorAck
1 DO 9 Y 1.0 GO[1] ActiveStyBit1 1 DI 9 X 1.0 GI[1] STYLEBit1
1 DO 16 Y 1.7 PrgPaused 1 DI 16 X 1.7 WeldGunForceChk
1 DO 17 Y 2.0 PrgRunning 1 DI 17 X 2.0 InterferenceClr1
1 DO 18 Y 2.1 RobotAtWork 1 DI 18 X 2.1 InterferenceClr2
1 DO 19 Y 2.2 WorkComplete 1 DI 19 X 2.2 AcceptVolume
1 DO 20 Y 2.3 20HourRunModeAct 1 DI 20 X 2.3 VolumeFltReset
1 DO 21 Y 2.4 GO[5] MaintReqBit1 1 DI 21 X 2.4 PPOK_ClrToGrip
1 DO 22 Y 2.5 GO[5] MaintReqBit2 1 DI 22 X 2.5 GripOK_ClrToExit
1 DO 23 Y 2.6 GO[5] MaintReqBit4 1 DI 23 X 2.6 AbortExitPick
1 DO 24 Y 2.7 GO[5] MaintReqBit8 1 DI 24 X 2.7 AbortExitDrop
1 DO 25 Y 3.0 RobotAtPounce 1 DI 25 X 3.0 RetFromPounce
1 DO 26 Y 3.1 RobotAtService 1 DI 26 X 3.1 ServiceCompltReq
1 DO 27 Y 3.2 RobotAtHome 1 DI 27 X 3.2 ServiceRequest
1 DO 28 Y 3.3 RobotInTipDress 1 DI 28 X 3.3 TipDressGunReq
1 DO 29 Y 3.4 TipDressComplt 1 DI 29 X 3.4 ProdStart
1 DO 30 Y 3.5 RdyForTipChg 1 DI 30 X 3.5 Spare
1 DO 31 Y 3.6 CleartoTransfer 1 DI 31 X 3.6 GoToWork
1 DO 32 Y 3.7 WldInPrgrsActiv1 1 DI 32 X 3.7 WorkCompleteAck
1 DO 33 Y 4.0 RbtClrZone1 1 DI 33 X 4.0 Zone1ClrToEnter
1 DO 39 Y 4.6 Spare 1 DI 39 X 4.6 Spare
1 DO 41 Y 5.0 UserOutput1 1 DI 41 X 5.0 UserInput1
1 DO 47 Y 5.6 Spare 1 DI 47 X 5.6 StudSlide1InPos
1 DO 48 Y 5.7 Spare 1 DI 48 X 5.7 StudSlide2InPos
1 DO 49 Y 6.0 ClrOfPickup1 1 DI 49 X 6.0 GoToPickup1
1 DO 50 Y 6.1 AtPickup1 1 DI 50 X 6.1 ExitPickup1
1 DO 51 Y 6.2 ClrOfDropoff1 1 DI 51 X 6.2 GoToDropoff1
1 DO 52 Y 6.3 AtDropoff1 1 DI 52 X 6.3 ExitDropoff1
1 DO 65 Y 8.0 Clr2UnclampEarly 1 DI 65 X 8.0 Part1InFixture
1 DO 66 Y 8.1 RbtAtUserPos1 1 DI 66 X 8.1 Part2InFixture
1 DO 70 Y 8.5 Spare 1 DI 70 X 8.5 Part6InFixture
1 DO 71 Y 8.6 Req2EntrToolNest 1 DI 71 X 8.6 App1ClrToEnter
AS OF 2/4/2011 17 CUSW REL1.1

PLC COMMUNICATIONS PLC COMMUNICATIONS
1 DO 72 Y 8.7 ClearOfToolNest 1 DI 72 X 8.7 App2ClrToEnter
1 DO 73 Y 9.0 ServiceComp 1 DI 73 X 9.0 ToolInNest1
1 DO 74 Y 9.1 MajorMinorFlt 1 DI 74 X 9.1 ToolInNest2
1 DO 75 Y 9.2 WaitingForPlcCmd 1 DI 75 X 9.2 ToolInNest3
1 DO 76 Y 9.3 RemoveFault 1 DI 76 X 9.3 ToolInNest4
1 DO 77 Y 9.4 RobotPartPres1 1 DI 77 X 9.4 GI[4] PickTool1
1 DO 81 Y 10.0 RobotPartPres5 1 DI 81 X 10.0 Clr2EntToolNest
1 DO 82 Y 10.1 RobotPartPres6 1 DI 82 X 10.1 GI[5] ToolingRepod1
1 DO 83 Y 10.2 Spare 1 DI 83 X 10.2 GI[5] ToolingRepod2
1 DO 84 Y 10.3 Spare 1 DI 84 X 10.3 GI[5] ToolingRepod4
1 DO 85 Y 10.4 Spare 1 DI 85 X 10.4 GI[6] PalletPosBit1
1 DO 89 Y 11.0 PickOverride 1 DI 89 X 11.0 GI[6] PalletPosBit16
1 DO 90 Y 11.1 CollisGuardEnbld 1 DI 90 X 11.1 GI[6] PalletPosBit32
1 DO 91 Y 11.2 AirPressAcptRng 1 DI 91 X 11.2 GI[6] PalletPosBit64
1 DO 92 Y 11.3 AirOK 1 DI 92 X 11.3 GI[6] PalletPosBit128
1 DO 93 Y 11.4 WetDryMode 1 DI 93 X 11.4 WetDryMode
1 DO 94 Y 11.5 AbortPickReq 1 DI 94 X 11.5 AbortReq
1 DO 95 Y 11.6 Spare 1 DI 95 X 11.6 PurgeGun1Req
1 DO 96 Y 11.7 Spare 1 DI 96 X 11.7 PurgeGun2Req
1 DO 97 Y 12.0 ExtPurg1InProgrs 1 DI 97 X 12.0 WaterFlowOK
1 DO 98 Y 12.1 ExtPurg2InProgrs 1 DI 98 X 12.1 Spare
1 DO 99 Y 12.2 WaterOn 1 DI 99 X 12.2 TipDressDumpExtd
1 DO 100 Y 12.3 WaterOff 1 DI 100 X 12.3 TipDrsDumpRetrct
1 DO 101 Y 12.4 TurnOnTipDresser 1 DI 101 X 12.4 TipDrsMotorOn
1 DO 102 Y 12.5 StepperRstAck 1 DI 102 X 12.5 ExtStepperReset1
1 DO 103 Y 12.6 StepMode 1 DI 103 X 12.6 ExtStepperReset2
1 DO 104 Y 12.7 RobotAtPurgePos 1 DI 104 X 12.7 TipBurnInReq
1 DO 105 Y 13.0 RobotClrFixt1 1 DI 105 X 13.0 TipChgReq
1 DO 106 Y 13.1 RobotClrFixt2 1 DI 106 X 13.1 InspectRequired
1 DO 107 Y 13.2 Spare 1 DI 107 X 13.2 InspectComplete
1 DO 108 Y 13.3 Spare 1 DI 108 X 13.3 ClrToExitUsrPos1
1 DO 109 Y 13.4 GO[2] ReposTooling1 1 DI 109 X 13.4 ClrToExitUsrPos2
1 DO 110 Y 13.5 GO[2] ReposTooling2 1 DI 110 X 13.5 ClrToExitUsrPos3
1 DO 111 Y 13.6 SignatureChgInd 1 DI 111 X 13.6 ClrToExitUsrPos4
1 DO 112 Y 13.7 RbtAtInspectPos 1 DI 112 X 13.7 ClrToExitUsrPos5
1 DO 113 Y 14.0 TeachPendantEnbd 1 DI 113 X 14.0 ExtApp1StartReq
1 DO 114 Y 14.1 StartExtApp1Proc 1 DI 114 X 14.1 ExtApp1Complete
1 DO 115 Y 14.2 StartExtApp1Proc 1 DI 115 X 14.2 ExtApp2StartReq
1 DO 116 Y 14.3 GO[3] ToolIDOnWrist1 1 DI 116 X 14.3 ExtApp2Complete
1 DO 117 Y 14.4 GO[3] ToolIDOnWrist2 1 DI 117 X 14.4 Reseal
1 DO 118 Y 14.5 GO[3] ToolIDOnWrist4 1 DI 118 X 14.5 RejectPart
1 DO 119 Y 14.6 ProcessFault 1 DI 119 X 14.6 NoSafeSpeed1
1 DO 120 Y 14.7 AppErrorActive 1 DI 120 X 14.7 ReweldStud
1 DO 121 Y 15.0 GO[4] AppErorrBit1 1 DI 121 X 15.0 AcceptStud
1 DO 122 Y 15.1 GO[4] AppErrorBit2 1 DI 122 X 15.1 RejectStud
1 DO 123 Y 15.2 GO[4] AppErrorBit4 1 DI 123 X 15.2 ChangedHead
1 DO 124 Y 15.3 GO[4] AppErrorBit8 1 DI 124 X 15.3 StudSlide1InPos
1 DO 125 Y 15.4 GO[4] AppErrorBit16 1 DI 125 X 15.4 StudSlide2InPos
1 DO 126 Y 15.5 GO[4] AppErrorBit32 1 DI 126 X 15.5 PickOverrideReq
1 DO 127 Y 15.6 GO[4] AppErrorBit64 1 DI 127 X 15.6 Spare
1 DO 128 Y 15.7 GO[4] AppErrorBit128 1 DI 128 X 15.7 NoSafeSpeed2
AS OF 2/4/2011 18 CUSW REL1.1

COMMUNICATIONS COMMUNICATIONS

DO 129 Y 0.0 Spare DI 129 X 0.0 Spare
DO 130 Spare DI 130 Spare
AS OF 2/4/2011 19 CUSW REL1.1

SPOT WELD SCR#1 COMMUNICATIONS SPOT WELD SCR#1 COMMUNICATIONS

11 DO 193 Y 0.0 W1EnableWld 11 DI 193 X 0.0 W1WeldEnabled
11 DO 194 W1FaultRst 11 DI 194 W1NoFault
11 DO 195 W1WldFltAck 11 DI 195 W1NoAlert
11 DO 196 GO[11] W1PrgBit1 11 DI 196 W1WeldFltAvail
11 DO 197 GO[11] W1PrgBit2 11 DI 197 GI[11] W1WeldFltBit1
11 DO 202 W1InitiateWld 11 DI 202 W1WeldComplete
11 DO 203 W1PressTest 11 DI 203 W1WeldInProgres
11 DO 204 W1InitRet 11 DI 204 W1SteppersReset
11 DO 205 W1RstStepper 11 DI 205 W1NearEndOfStep
11 DO 206 W1IsoContSvrEnb 11 DI 206 W1EndOfStepper
11 DO 207 W1ControlStop 11 DI 207 W1ReadyToWeld
11 DO 208 W1Tipsdressed 11 DI 208 W1DressTipsReq
11 DO 209 GO[12] W1WldIDBit1 11 DI 209 W1RetractOut#1
11 DO 211 GO[12] W1WldIDBit4 11 DI 211 W1FltMSGCode
11 DO 212 GO[12] W1WldIDBit8 11 DI 212 W1AlrtMSGCode
11 DO 213 GO[12] W1WldIDBit16 11 DI 213 Spare
11 DO 223 Spare 11 DI 223 Spare


AS OF 2/4/2011 20 CUSW REL1.1




AS OF 2/4/2011 21 CUSW REL1.1

NELSON STUD WELDER COMMUNICATIONS NELSON STUD WELDER COMMUNICATIONS

16 DO 321 Y 0.0 StartWeld1 16 DI 321 X 0.0 NOError1
16 DO 322 StartWeld2 16 DI 322 WeldComp1
16 DO 323 StartWeld3 16 DI 323 WeldGunRetrctd1
16 DO 324 StartWeld4 16 DI 324 StudTouchingWrk1
16 DO 325 StartWeld5 16 DI 325 SuspectWeld1
16 DO 326 FeedStud1 16 DI 326 NOError2
16 DO 327 FeedStud2 16 DI 327 WeldComp2
16 DO 328 FeedStud3 16 DI 328 WeldGunRetrctd2
16 DO 329 FeedStud4 16 DI 329 StudTouchingWrk2
16 DO 330 FeedStud5 16 DI 330 SuspectWeld2
16 DO 331 GO[21] SelectProgBit1 16 DI 331 NOError3
16 DO 332 GO[21] SelectProgBit2 16 DI 332 WeldComp3
16 DO 333 GO[21] SelectProgBit4 16 DI 333 WeldGunRetrctd3
16 DO 334 GO[21] SelectProgBit8 16 DI 334 StudTouchingWrk3
16 DO 335 GO[21] SelectProgBit16 16 DI 335 SuspectWeld3
16 DO 336 GO[21] SelectProgBit32 16 DI 336 NOError4
16 DO 337 GO[21] SelectProgBit64 16 DI 337 WeldComp4
16 DO 338 GO[21] SelectProgBit128 16 DI 338 WeldGunRetrctd4
16 DO 339 Restart 16 DI 339 StudTouchingWrk4
16 DO 340 SetWeldComp 16 DI 340 SuspectWeld4
16 DO 341 GO[22] SelectOperMode0 16 DI 341 NOError5
16 DO 342 GO[22] SelectOperMode1 16 DI 342 WeldComp5
16 DO 343 ResetFault 16 DI 343 WeldGunRetrctd5
16 DO 344 Std1Output24 16 DI 344 StudTouchingWrk5
16 DO 345 Std1Output25 16 DI 345 SuspectWeld5
16 DO 346 Std1Output26 16 DI 346 MaintCountReachd
16 DO 347 Std1Output27 16 DI 347 FeederLow
16 DO 348 Std1Output28 16 DI 348 UnitOnline
16 DO 349 Std1Output29 16 DI 349 AllGunsReady
16 DO 350 Std1Output30 16 DI 350 SimModeActive
16 DO 351 Std1Output31 16 DI 351 Std1Input31
16 DO 353 Std1Output33 16 DI 353 GI[22] ErrorCodeBit1
16 DO 369 AdvWeldGun1 16 DI 369 Std1Input49
AS OF 2/4/2011 22 CUSW REL1.1

NORDSON DISPENSE #1 COMMUNICATIONS NORDSON DISPENSE #1 COMMUNICATIONS

25 DO 385 Y 0.0 GO[31] Disp1StyBit1 25 DI 385 X 0.0 Dsp1DispenRdy
25 DO 386 GO[31] Disp1StyBit2 25 DI 386 Dsp1DispenInPrc
25 DO 387 GO[31] Disp1StyBit3 25 DI 387 Dsp1VolumeOK
25 DO 388 GO[31] Disp1StyBit4 25 DI 388 Reserved
25 DO 389 GO[31] Disp1StyBit5 25 DI 389 Dsp1MinorFault
25 DO 393 Disp1RbtinPrc 25 DI 393 Dsp1LowVolFlt
25 DO 394 Disp1StyStrobe 25 DI 394 Dsp1HighVolFlt
25 DO 395 Disp1GunON 25 DI 395 Dsp1LowPressFlt
25 DO 396 Disp1PurgeCP-2K 25 DI 396 Dsp1HighPressFlt
25 DO 397 Reserved 25 DI 397 Dsp1ColDetd
25 DO 398 Reserved 25 DI 398 Reserved
25 DO 401 Disp1Complete 25 DI 401 Reserved
25 DO 402 Disp1RemoteStart 25 DI 402 Reserved
Disp1PurgeCP
25 DO 416 25 DI 416 Reserved
Clr2AutoPurg2K
25 DO 417 GO[32] Dsp1MatFlwCmdB1 25 DI 417 Reserved
25 DO 448 Disp1FaultRst 25 DI 448 Reserved
AS OF 2/4/2011 23 CUSW REL1.1

NORDSON DISPENSE #2 COMMUNICATIONS NORDSON DISPENSE #2 COMMUNICATIONS

26 DO 449 Y 0.0 GO[36] Disp2StyBit1 26 DI 449 X 0.0 Dsp2DispenRdy
26 DO 450 GO[36] Disp2StyBit2 26 DI 450 Dsp2DispenInPrc
26 DO 451 GO[36] Disp2StyBit3 26 DI 451 Dsp2VolumeOK
26 DO 453 GO[36] Disp2StyBit5 26 DI 453 Dsp2MinorFault
26 DO 457 Disp2RbtinPrc 26 DI 457 Dsp2LowVolFlt
26 DO 458 Disp2StyStrobe 26 DI 458 Dsp2HighVolFlt
26 DO 459 Disp2GunON 26 DI 459 Dsp2LowPressFlt
26 DO 460 Disp2PurgeCP-2K 26 DI 460 Dsp2HighPressFlt
26 DO 461 Reserved 26 DI 461 Dsp2ColDetd
26 DO 465 Disp2Complete 26 DI 465 Reserved
26 DO 466 Disp2RemoteStart 26 DI 466 Reserved
Disp2PurgeCP
26 DO 480 26 DI 480 Reserved
Clr2AutoPurg2K
26 DO 512 Disp2FaultRst 26 DI 512 Reserved
AS OF 2/4/2011 24 CUSW REL1.1

MH EOAT MODULE #1 OUTPUT COMMUNICATIONS (SMC) MH EOAT MODULE #1 INPUT COMMUNICATIONS
ROBOT
NODE ROBOT PMC INTERNAL NODE ROBOT PMC GROUP
39 DO 513 K0.0 DO 10001 VLV1Extend 31 DI 513 X 0.0 Part1Present
39 DO 514 K0.1 DO 10002 VLV1Retract 31 DI 514 Part2Present
39 DO 515 K0.2 DO 10003 VLV2Extend 31 DI 515 Part3Present
39 DO 517 K0.4 DO 10005 VLV3Extend 31 DI 517 MHDev1Retracted
39 DO 518 K0.5 DO 10006 VLV3Retract 31 DI 518 MHDev1Extended
39 DO 529 K2.0 DO 10017 VLV9Extend
39 DO 530 K2.1 DO 10018 VLV9Retract ROBOT INPUTS

39 DO 531 K2.2 DO 10019 VLV10Extend MH EOAT MODULE #2 INPUT COMMUNICATIONS
39 DO 532 K2.3 DO 10020 VLV10Retract NODE ROBOT PMC GROUP

ADDRESS ADDRESS ADDRESS ASSIGNMENT SIGNAL NAME
39 DO 533 K2.4 DO 10021 VLV11Extend 32 DI 529 X 0.0 Part5Present
39 DO 535 K2.6 DO 10023 VLV12Extend 32 DI 531 Part7Present
32 DI 541 MHDev11Retracted
32 DI 542 MHDev11Extended
AS OF 2/4/2011 25 CUSW REL1.1

ROBOT OUTPUTS
MH EOAT MODULE MISC OUTPUT COMMUNICATIONS ROBOT INPUTS
(AB) COMBO EOAT VAC/CLAMPS/MISC MH EOAT MODULE #3 INPUT COMMUNICATIONS

36 DO 545 Y 0.0 User Define Output1 33 DI 545 X 0.0 Part9Present
36 DO 546 User Define Output2 33 DI 546 Part10Present
36 DO 549 User Define Output5 33 DI 549 MHDev13Retracted
36 DO 550 User Define Output6 33 DI 550 MHDev13Extended
36 DO 561 User Define Output17
36 DO 562 User Define Output18 ROBOT INPUTS

36 DO 563 User Define Output19 MH EOAT MODULE #4 INPUT COMMUNICATIONS
36 DO 564 User Define Output20 NODE ROBOT PMC GROUP

36 DO 565 User Define Output21 34 DI 561 X 0.0 MHDev19Retracted
ROBOT OUTPUTS 34 DI 574 MHDev25Extended
OUTPUT COMMUNICATIONS 34 DI 575 MHDev26Retracted
NODE ROBOT PMC GROUP 34 DI 576 MHDev26Extended

DO 577 Spare
DO 578 Spare ROBOT INPUTS

DO 579 Spare MH EOAT MODULE #5 INPUT COMMUNICATIONS
DO 580 Spare NODE ROBOT PMC GROUP

DO 581 Spare 35 DI 577 X 0.0 MHDev27Retracted
DO 582 Spare 35 DI 578 MHDev27Extended
DO 583 Spare 35 DI 579 MHDev28Retracted
DO 584 Spare 35 DI 580 MHDev28Extended
DO 585 Spare 35 DI 581 MHDev29Retracted
ROBOT OUTPUTS 35 DI 583 MHDev30Retracted
SPOT TP LOGIC COMMUNICATIONS 35 DI 584 MHDev30Extended
NODE ROBOT PMC GROUP 35 DI 585 MHDev31Retracted

RbtInternal DO 586 Y0073.1 W1RstWtrSvr 35 DI 586 MHDev31Extended
RbtInternal DO 587 Y0073.2 W1WtrOff 35 DI 587 MHDev32Retracted
RbtInternal DO 588 Y0073.3 W2RstWtrSvr 35 DI 588 MHDev32Extended
RbtInternal DO 589 Y0073.4 W2WtrOff 35 DI 589 MHDev33Retracted
RbtInternal DO 590 Y0073.5 W1RstStepper 35 DI 590 MHDev33Extended
RbtInternal DO 591 Y0073.6 W2RstStepper 35 DI 591 MHDev34Retracted
AS OF 2/4/2011 26 CUSW REL1.1

ROBOT OUTPUTS
MH EOAT COMMUNICATIONS
NODE ROBOT PMC GROUP

RbtInternal DO 592 MH_MAJORFLT

MH EOAT VAC MODULE #1 OUTPUT COMMUNICATIONS MH EOAT VAC MODULE #1 INPUT COMMUNICATIONS

37 DO 593 Y 0.0 doVacCH1On 37 DI 593 X 0.0 VacuumCH1PP
37 DO 594 doBlwOffCh1On 37 DI 594 VacuumCH2PP
37 DO 595 doVacCH2On 37 DI 595 VacuumCH3PP
37 DO 597 doVacCH3On 37 DI 597
37 DO 598 doBlwOffCh3On 37 DI 598

MH EOAT VAC MODULE #2 OUTPUT COMMUNICATIONS MH EOAT VAC MODULE #2 INPUT COMMUNICATIONS

38 DO 601 Y 0.0 doVacCH5On 38 DI 601 X 0.0 VacuumCH5PP
38 DO 603 doVacCH6On 38 DI 603 VacuumCH7PP

USER DEFINABLE IO #1 COMMUNICATIONS (AB) USER DEFINABLE IO #1 COMMUNICATIONS (AB)

43 DO 609 Y 0.0 UserDefineddo609 43 DI 609 X 0.0 UserDefineddi609
43 DO 610 UserDefineddo610 43 DI 610 UserDefineddi610

USER DEFINABLE IO #2 COMMUNICATIONS (AB) USER DEFINABLE IO #2 COMMUNICATIONS (AB)

44 DO 617 Y 0.0 UserDefineddo617 44 DI 617 X 0.0 UserDefineddi617
AS OF 2/4/2011 27 CUSW REL1.1

COMMUNICATIONS SMC PRESURE SWITCH COMMUNICATIONS

DO 625 Y 0.0 Spare 39 DI 625 X 0.0 Air Aceptable range
DO 626 Spare 39 DI 626 Air OK
DO 627 Spare 39 DI 627 Spare

ATI TOOLCHANGER COMMUNICATIONS ATI TOOLCHANGER COMMUNICATIONS

54 DO 632 Y 0.0 LatchOrLock 54 DI 632 X 0.0 ToolLocked
54 DO 633 UnlatchOrUnlock 54 DI 633 ToolUnLocked
54 DO 634 Spare 54 DI 634 DNetPowerOK
54 DO 635 ClearErrs 54 DI 635 AuxPowerOK
54 DO 636 ManualModeActd 54 DI 636 ReadyToLock1
54 DO 637 OutOfNest 54 DI 637 ReadyToLock2
54 DO 638 Spare 54 DI 638 ReadyToLockV1
54 DO 639 Spare 54 DI 639 ReadyToLockV2
54 DI 640 ToolStndIntlkV1
ROBOT OUTPUTS 54 DI 641 ToolStndIntlkV2
ATI TOOLCHANGER (ROBOT USER DEFINED) COMM. 54 DI 642 ToolStndRelayV1
NODE ROBOT PMC GROUP 54 DI 643 ToolStndRelayV2

N/A DO 640 ToolNotPresent 54 DI 644 ToolPresent
N/A DO 641 InvalidToolRqst 54 DI 645 ReservedTooldi13
N/A DO 642 UnexpctdTlPrsnt 54 DI 646 ReservedTooldi14
N/A DO 643 NestNotEmpty 54 DI 647 ReservedTooldi15
N/A DO 644 NestIsEmpty 54 DI 648 RTLMismatch
N/A DO 645 GeneralFaults 54 DI 649 TSIVMismatch
N/A DO 646 Reference Position 11 UnCoupleToolPos1 54 DI 650 LatchOverLoad
N/A DO 647 Reference Position 12 UnCoupleToolPos2 54 DI 651 UnlatchOverLoad
N/A DO 648 Reference Position 13 UnCoupleToolPos3 54 DI 652 SpareOverload
N/A DO 649 Reference Position 14 UnCoupleToolPos4 54 DI 653 RTLrtlvMismatch
N/A DO 650 Reference Position 15 UnCoupleToolPos5 54 DI 654 TSIVtsrvMismatch
N/A DO 651 Reference Position 16 UnCoupleToolPos6 54 DI 655 UnsafeUnlatch
N/A DO 652 Reference Position 17 UnCoupleToolPos7 54 DI 656 LckUnlckSensFlt
N/A DO 653 Reference Position 18 UnCoupleToolPos8 54 DI 657 LatchNotComplt
N/A DO 654 RbtOKtoUnCouple 54 DI 658 UnlatchNotComplt
54 DI 659 TSIVFault
54 DI 660 RTLFault
ROBOT OUTPUTS 54 DI 661 CommError
ROBOT INTERNAL COMMUNICATIONS 54 DI 662 ReservedTooldi30
NODE ROBOT PMC GROUP 54 DI 663 ReservedTooldi31

DO 655 Spare 54 DI 664 GI[41] ToolIDswtch1bit1
DO 667 Spare 54 DI 676 GI[44] ToolIDSwtch4bit1
DO 675 Spare 54 DI 684 UnlatchEnabled
AS OF 2/4/2011 28 CUSW REL1.1

DO 676 Spare 54 DI 685 ReservedTooldi53
DO 687 Spare
DO 688 Spare
DO 689 Spare
DO 690 Spare
DO 691 Spare
DO 692 Spare
DO 693 Spare
DO 694 Spare
DO 695 Spare

FORM & PIERCE MOOG COMMUNICATIONS FORM & PIERCE MOOG COMMUNICATIONS

48 DO 696 Y 0.0 doDrvAReset 48 DI 696 X 0.0 diDrvA_Ok
48 DO 697 48 DI 697 diDrvA_On
48 DO 698 doDrvAMode1Sel 48 DI 698
48 DO 699 doDrvAMode2Sel 48 DI 699 diDrvAHomeComp
48 DO 700 doStyleDrvALub 48 DI 700 diDrvAForce_Lub
48 DO 701 doDrvAAutomode 48 DI 701 diDrvAReturned
48 DO 702 48 DI 702 diDrvAAtPos
48 DO 703 doDrvBReset 48 DI 703
48 DO 704 48 DI 704 diDrvAMode1Ackn
48 DO 705 doDrvBMode1Sel 48 DI 705 diDrvAMode2Ackn
48 DO 706 doDrvBMode2Sel 48 DI 706
48 DO 707 doStyleDrvBLub 48 DI 707 diSr400On
48 DO 708 doDrvBAutomode 48 DI 708 diSrFuseOk
48 DO 709 48 DI 709
48 DO 710 48 DI 710
48 DO 711 48 DI 711
48 DO 712 doDrvATorqEnble 48 DI 712 diDrvB_Ok
48 DO 713 48 DI 713 diDrvB_On
48 DO 714 doDrvAExtPos1 48 DI 714
48 DO 715 doDrvARetPos2 48 DI 715 diDrvBHomeComp
48 DO 716 doDrvAPosSel 48 DI 716 diDrvBForce_Lub
48 DO 717 48 DI 717 diDrvBReturned
48 DO 718 48 DI 718 diDrvBAtPos
48 DO 719 48 DI 719
48 DO 720 doDrvBTorqEnble 48 DI 720 diDrvBMode1Ackn
48 DO 721 48 DI 721 diDrvBMode2Ackn
48 DO 722 doDrvBExtPos1 48 DI 722
48 DO 723 doDrvBRetPos2 48 DI 723
48 DO 724 doDrvBPosSel 48 DI 724
48 DO 725 48 DI 725
48 DO 726 48 DI 726
48 DO 727 48 DI 727
AS OF 2/4/2011 29 CUSW REL1.1

FORM & PIERCE CLINCH NUT-FEEDER COMMUNICATIONS FORM & PIERCE CLINCH NUT-FEEDER COMMUNICATIONS

49 DO 728 doExtendPusher 49 DI 728 diPusherExtended
49 DO 729 doReturnPusher 49 DI 729 diPusherReturned
49 DO 730 doExtendPlunger 49 DI 730 diPlungerRetrned
49 DO 731 doReturnPlunger 49 DI 731 diPlungerExtnded
49 DO 732 49 DI 732 diClinchAirOk
49 DO 733 49 DI 733
49 DO 734 49 DI 734 diFdNutPresent
49 DO 735 49 DI 735
49 DO 736 49 DI 736
49 DO 737 49 DI 737
49 DO 738 49 DI 738
49 DO 739 49 DI 739
49 DO 740 49 DI 740
49 DO 741 49 DI 741
49 DO 742 49 DI 742
49 DO 743 49 DI 743

FORM & PIERCE CLINCH NUT-TOOL COMMUNICATIONS FORM & PIERCE CLINCH NUT-TOOL COMMUNICATIONS

50 DO 744 doWkSupRetract 50 DI 744 diRbtNutPresent
50 DO 745 50 DI 745 diWorkSptRet
50 DO 746 50 DI 746
50 DO 747 50 DI 747
50 DO 748 50 DI 748
50 DO 749 50 DI 749
50 DO 750 50 DI 750
50 DO 751 50 DI 751
50 DO 752 50 DI 752
50 DO 753 50 DI 753
50 DO 754 50 DI 754
50 DO 755 50 DI 755
50 DO 756 50 DI 756
50 DO 757 50 DI 757
50 DO 758 50 DI 758
50 DO 759 50 DI 759

FORM & PIERCE PUMP COMMUNICATIONS FORM & PIERCE PUMP COMMUNICATIONS

51 DO 760 doChrgAccumultor 51 DI 760 diRobotAirOk
51 DO 761 51 DI 761
51 DO 762 doExtIntensCyl 51 DI 762 diWkAtPressure
51 DO 763 doRetIntensCyl 51 DI 763
51 DO 764 51 DI 764 diIntensCylRetd
51 DO 765 51 DI 765
51 DO 766 51 DI 766
51 DO 767 51 DI 767
NOT USED
AS OF 2/4/2011 30 CUSW REL1.1

TOOLCHANGER COVER / NEST #1 COMMUNICATIONS TOOLCHANGER COVER / NEST #1 COMMUNICATIONS

55 DO Y 0.0 Close Cover #1 55 DI X 0.0 Cover #1 Closed
55 DO Open Cover #1 55 DI Cover #1 Open
55 DO 55 DI Tool in nest #1 switch 1
55 DO 55 DI
55 DO 55 DI
55 DO 55 DI
55 DO 55 DI


56 DO 56 DI
56 DO 56 DI
56 DO 56 DI
56 DO 56 DI


57 DO 57 DI
57 DO 57 DI
57 DO 57 DI
57 DO 57 DI


58 DO 58 DI
58 DO 58 DI
58 DO 58 DI
58 DO 58 DI
AS OF 2/4/2011 31 CUSW REL1.1

SPARE SPARE


SPARE SPARE

AS OF 2/4/2011 32 CUSW REL1.1

SPARE SPARE


SPARE SPARE


AS OF 2/4/2011 33 CUSW REL1.1

ISRA VISION COMMUNICATIONS ISRA VISION COMMUNICATIONS

60 DO 913 Y 0.0 GO[38] doISRA_CmdB1 60 DI 913 X 0.0 GI[31] diISRA_StatBit1
60 DO 914 GO[38] doISRA_CmdB2 60 DI 914 GI[31] diISRA_StatBit2
60 DO 917 doISRA_Strt_M 60 DI 917 diISRA_Ready
60 DO 918 doISRA_reservd 60 DI 918 diISRA_Snap_ip
60 DO 919 GO[40] doISRA_Rst_E 60 DI 919 diISRA_Data_ip
60 DO 920 doISRA_ID_Valid 60 DI 920 diISRA_ID_OK
60 DO 921 GO[39] doISRA_TpIDB1 60 DI 921 GI[38] diISRA_reservd
60 DO 922 GO[39] doISRA_TpIDB2 60 DI 922 GI[38] diISRA_ErrPLC
60 DO 923 GO[39] doISRA_TpIDB4 60 DI 923 GI[38] diISRA_ErrRbt
60 DO 924 GO[39] doISRA_TpIDB8 60 DI 924 GI[38] diISRA_OutTol
60 DO 925 GO[39] doISRA_TpIDB16 60 DI 925 GI[38] diISRA_Disabl
60 DO 926 GO[39] doISRA_TpIDB32 60 DI 926 GI[38] diISRA_ErrImage
60 DO 927 GO[39] doISRA_TpIDB64 60 DI 927 GI[38] diISRA_reservd1
60 DO 928 GO[39] doISRA_TpIDB128 60 DI 928 GI[38] diISRA_ErrDet
60 DO 929 GO[41] doISRA_SubStyle 60 DI 929 GI[32] diISRA_XB1
60 DO 937 GO[42] doISRA_Color 60 DI 937 GI[32] diISRA_XB256
60 DI 945 GI[33] diISRA_YB1
ROBOT OUTPUTS 60 DI 946 GI[33] diISRA_YB2
APP. ERROR CODE (ROBOT USER DEFINED) COMM. 60 DI 947 GI[33] diISRA_YB4
NODE ROBOT PMC GROUP 60 DI 948 GI[33] diISRA_YB8

N/A DO 945 N/A AppErrSpare01 60 DI 949 GI[33] diISRA_YB16
N/A DO 957 N/A AppErrSpare13 60 DI 961 GI[34] diISRA_ZB1
N/A DO 973 N/A AppErrSpare29 60 DI 977 GI[35] diISRA_RXB1
AS OF 2/4/2011 34 CUSW REL1.1

N/A DO 989 N/A AppErrSpare45 60 DI 993 GI[36] diISRA_RYB1
N/A DO 1005 N/A AppErrSpare61 60 DI 1009 GI[37] diISRA_RZB1
N/A DO 1021 N/A AppErrSpare77

ROBOT INTERNAL COMMUNICATIONS ROBOT INTERNAL COMMUNICATIONS

RbtInternal DO 901 WaterValve1ON RbtInternal DI 901 WaterFlowOK1
RbtInternal DO 902 WaterValve1OFF RbtInternal DI 902
RbtInternal DO 903 RbtInternal DI 903 WaterFlowOK2
RbtInternal DO 904 WaterValve2ON RbtInternal DI 904
RbtInternal DO 905 WaterValve2OFF RbtInternal DI 905
RbtInternal DO 906 RbtInternal DI 906
RbtInternal DO 907 VacuumCH_ON RbtInternal DI 907 VacuumCH_ON
RbtInternal DO 908 RbtInternal DI 908
RbtInternal DO 909 XFORMTEMPOk1 RbtInternal DI 909 XFORMTEMPOk1
AS OF 2/4/2011 35 CUSW REL1.1

ROBOT APPLICATION ERROR TIMING
SYNCHRONIZE PLC / IDENTIFY TOP OF PMC LOGIC

Application Error Bits GO[4] = FIS ID
(Group Output) LOW State
DO[121 – 128]
Error Active goes LOW when Error Ack goes HIGH
Application Error
Active DO[120]
Application Error
Acknowledge Error Ack goes LOW when Error Active goes LOW DI[8]
(PLC Signal)
LOOP Until ALL Application Errors (if applicable) is monitored
ADDING APPLICATION ERROR BITS TO PLC

Application Error Bits
(Group Output) GO[4] = FIS ID
DO[121 – 128]
a
Application Error
Active Error Active goes LOW when Error Ack goes HIGH
DO[120]
Application Error
Acknowledge Error Ack goes LOW when Error Active goes LOW DI[8]
(PLC Signal)
LOOP Until ALL Application Errors (if applicable) is monitored
REMOVING APPLICATION ERROR BITS FROM PLC

Application Error Bits
(Group Output) GO[4] = FIS ID
DO[121 – 128]
Application Error
Remove Error Active goes LOW when Error Ack goes HIGH
DO[76]
a
Application Error
Active b Error Active goes LOW when
b Error Ack goes HIGH
DO[120]
Application Error
Acknowledge Error Ack goes LOW when Error Active goes LOW
DI[8]
(PLC Signal)
a = 500 msec
ROBOT INPUTS FROM PLC ROBOT OUTPUTS TO PLC Not Robot I/O
AS OF 2/4/2011 36 CUSW REL1.1

ROBOT APPLICATION ERRORS
GROUP ERROR PLC

INPUT/S DESCRIPTION IO STATE
INPUT SEVERITY CODE
INTERNAL ROBOT HANDSHAKE TO PLC

N/A N/A Clear all faults command ID N/A 0 N/A
SPARE
1
2
3
4
CLINCH NUT
No Nut In Anvil 5
Feeder Air Not On 6
Clinch Nut Still in Anvil 7
Clinch Nut Not Present at Feeder 8
Nut Feeder Plunger Not In Position 9
Clinch Nut Part Present Fault 10
Nut Feeder Pusher Not In Position 11
NET-FORM-PIERCE
Work Support Pressure Fault 12
Moog Mode Fault 13
Moog Drive A OK Fault 14
Moog Drive B OK Fault 15
Moog Drive A ON Fault 16
Moog Drive B ON Fault 17
Moog Drive A Position Fault 18
Moog Drive B Position Fault 19
Moog Drive A Force Fault 20
Moog Drive B Force Fault 21
QMC/FMS
AAC Error Major 22
AAC Required Major 23
ATC Error Major 24
ATC Required Major 25
ATC Expired Major 26
Vision Comm Heartbeat Lost Major 27
Vision System App Fault Major 28
29
30
31
32
AS OF 2/4/2011 37 CUSW REL1.1

GROUP ERROR PLC
INPUT SEVERITY CODE
SPOTWELDING
DI 197 -201 GI[11]
I/O Error Major/Minor 33 N/A
DI 229 -233 GI[13]
DI 197 -201 GI[11]
I/O Alarm Major/Minor 34 N/A
DI 229 -233 GI[13]
DI 197 -201 GI[11]
Incomplete Weld Major/Minor 35 N/A
DI 229 -233 GI[13]
DI 197 -201 GI[11]
Stepper Approaching Max Major/Minor 36 N/A
DI 229 -233 GI[13]
DI 197 -201 GI[11]
End Of Stepper Major/Minor 37 N/A
DI 229 -233 GI[13]
DI 197 -201 GI[11]
Sure Weld Trend Limit Major/Minor 38 N/A
DI 229 -233 GI[13]
DI 197 -201 GI[11]
High/Low Current Limit Major/Minor 39 N/A
DI 229 -233 GI[13]
DI 197 -201 GI[11]
Firing Error Major/Minor 40 N/A
DI 229 -233 GI[13]
DI 197 -201 GI[11]
Cylinder Fault Major/Minor 41 N/A
DI 229 -233 GI[13]
DI 197 -201 GI[11]
Cylinder Alarm Major/Minor 42 N/A
DI 229 -233 GI[13]
DI 197 -201 GI[11]
Power Factor Error Major/Minor 43 N/A
DI 229 -233 GI[13]
DI 197 -201 GI[11]
Compensation Error Major/Minor 44 N/A
DI 229 -233 GI[13]
DI 197 -201 GI[11]
Insufficient Line Voltage Major/Minor 45 N/A
DI 229 -233 GI[13]
DI 197 -201 GI[11]
Extend Weld Major/Minor 46 N/A
DI 229 -233 GI[13]
DI 197 -201 GI[11]
Isolation Contactor Error Major/Minor 47 N/A
DI 229 -233 GI[13]
DI 197 -201 GI[11]
Welding Buss Voltage Major/Minor 48 N/A
DI 229 -233 GI[13]
DI 197 -201 GI[11]
Weld Data Not Programmed Major/Minor 49 N/A
DI 229 -233 GI[13]
DI 197 -201 GI[11]
Analog Pressure Error Major/Minor 50 N/A
DI 229 -233 GI[13]
DI 197 -201 GI[11]
C-Factor Limit Major/Minor 51 N/A
DI 229 -233 GI[13]
DI 197 -201 GI[11]
Secondary Current Major/Minor 52 N/A
DI 229 -233 GI[13]
DI 197 -201 GI[11]
Welding Transformer Major/Minor 53 N/A
DI 229 -233 GI[13]
DI 197 -201 GI[11]
Over Temperature Major/Minor 54 N/A
DI 229 -233 GI[13]
DI 197 -201 GI[11]
Shorted SCR Major/Minor 55 N/A
DI 229 -233 GI[13]
DI 197 -201 GI[11]
Internal Timer Error Major/Minor 56 N/A
DI 229 -233 GI[13]
DI 197 -201 GI[11]
Inverter Fault Major/Minor 57 N/A
DI 229 -233 GI[13]
DI 197 -201 GI[11]
Timer Not Ready Major/Minor 58 N/A
DI 229 -233 GI[13]
DI 197 -201 GI[11]
Reserved Major/Minor 59 N/A
DI 229 -233 GI[13]
DI 197 -201 GI[11]
DI 229 -233 GI[13]
DI 197 -201 GI[11]
DI 229 -233 GI[13]
AS OF 2/4/2011 38 CUSW REL1.1
GROUP ERROR PLC
INPUT SEVERITY CODE
DI 197 -201 GI[11]
DI 229 -233 GI[13]
DI 197 -201 GI[11]
DI 229 -233 GI[13]
WATER SAVER
DI 785 N/A W1OKtoWeld Major 64 N/C
DI 787 N/A 65 N/O
DI 817 N/A 66 N/C

DI 819 N/A 67 N/O
WELD SERVOGUN / ARC

SPOT-068 N/A ServoGun Faulted 68
ARC-006 N/A Wire Fault 69
ARC-008 N/A Power Supply Fault 70
ARC-010 N/A Wire stick detected 71
ARC-013 N/A Arc Start failed 72
ARC-017 N/A Arc Start was Disabled 73
ARC-018 N/A Lost arc detect 74
ARC-030 N/A Wire stick is still detected 75
ARC-033 N/A Override must be 100% to weld 76
INTERNAL ROBOT
N/A Transformer over temperature Major 77
TOOL CHANGER
DO 640 N/A ToolNotPresent 78 N/O
DO 641 N/A Invalid Tool Requested 79 N/O
DI 648 N/A RTLMismatch 80 N/O
DI 649 N/A TSIVMismatch 81 N/O
DI 650 N/A LatchOverLoad 82 N/O
DI 651 N/A UnlatchOverLoad 83 N/O
DI 652 N/A SpareOverload 84 N/O
DI 653 N/A RTLrtlvMismatch 85 N/O
DI 654 N/A TSIVtsrvMismatch 86 N/O
DI 655 N/A UnsafeUnlatch 87 N/O
DI 656 N/A LckUnlckSensFlt 88 N/O
DI 657 N/A LatchNotComplt 89 N/O
DI 658 N/A UnlatchNotComplt 90 N/O
DI 659 N/A TSIVFault 91 N/O
DI 660 N/A RTLFault 92 N/O
DI 661 N/A Comm Error 93 N/O
DI 684 N/A Unlatch Enabled 94 N/C
DI 634 N/A DNetPowerNotPresent 95 N/O
DI 635 N/A AuxPowerNotPresent 96 N/O
DO 642 N/A Unexpected Tool Present 97 N/O
DO 643 N/A Nest not empty 98 N/O
DO 644 N/A Nest is empty 99 N/O
STUD WELDING
DI 321 N/A NOError1 Major 100 N/C
DI 347 N/A Std1StudsLow Minor 105 N/O
DI 348 N/A Std1ReadyForAuto Major 106 N/O
DI 349 N/A Std1ReadyToWeld Major 107 N/C
AS OF 2/4/2011 39 CUSW REL1.1

SPARE
108
109
110
111
112
113
114
115
116
117
118
119
NORDSON DISPENSING #1
120
121
DI 393 N/A Nozzle 1 Low Volume Fault Major 122 N/C
DI 394 N/A Nozzle 1 High Volume Fault Major 123 N/C
DI397 N/A Nozzle 1 Collision Detected Major 124
Di395 N/A Dispense 1 Low Pressure Fault Major 125
DI396 N/A Dispense 1 High Pressure Fault Major 126
DI389 N/A Dispense 1 Minor Alarm Minor 127
N/A Dispense 1 Communication Fault to Robot Major 128
t 129
NORDSON DISPENSING #2
130
131
DI 457 N/A Nozzle 2 Low Volume Fault Major 132 N/C
DI 458 N/A Nozzle 2 High Volume Fault Major 133 N/C
DI461 N/A Nozzle 2 Collision Detected Major 134
DI458 N/A Dispense 2 Low Pressure Fault Major 135
DI459 N/A Dispense 2 High Pressure Fault Major 136
DI457 N/A Dispense 2 Minor Alarm Minor 137
N/A Dispense 2 Communication Fault to Robot Major 138
139
140
PERCEPTRON VISION
Perceptron Communication Fault Major 141 N/O
Perceptron Status Fault Major 142 N/O
Perceptron Bad Measurement Major 143 N/O
General Search Error Major 144 N/O
145
DYNALOG MEASUREMENT
Dynalog Major Fault Major 146 N/O
Dynalog Minor Fault Major 147 N/O
SPARE
148
149
150
AS OF 2/4/2011 40 CUSW REL1.1

ISRA VISION
DI 917 N/A diISRA_Ready Major 150
DI 918 N/A diISRA_Meas_ip Major 151
DI 919 N/A diISRA_Data_ip Major 152
DI 920 N/A diISRA_ID_OK Major 153
DI 922 N/A diISRA_ErrPLC Major 154
DI 923 N/A diISRA_ErrRbt Major 155
DI 924 N/A diISRA_OutTol Major 156
DI 925 N/A diISRA_Disabl Major 157
DI 926 N/A diISRA_ErrImage Major 158
DI 928 N/A diISRA_ErrDet Major 159
MATERIAL HANDLING/VISION
Rack not open fault Major 160 N/O
Part search fault Major 161 N/O
SPARE
162
163
MATERIAL HANDLING
N/A N/A VacuumCH1PP Fault Major/Minor 164 EVENT DRIVEN
N/A N/A Part Present 1 Fault Major/Minor 176 EVENT DRIVEN
N/A N/A MH Device 1 Retract Fault Major/Minor 188 EVENT DRIVEN
AS OF 2/4/2011 41 CUSW REL1.1
N/A N/A MH Device 1 Extend Fault Major/Minor 222 EVENT DRIVEN
Note: If a Material Handling Fault is disabled using the DF&C function, the appropriate application error bit will be posted as a MINOR fault
indicating that the MAJOR fault is disabled. The Process Fault bit will remain low.
AS OF 2/4/2011 42 CUSW REL1.1

PLC LOGIC REFERENCE
The 10WD program will utilize Allen-Bradley GuardLogix Processors with DeviceNet for PLC to Robot and Robot to PLC communications.
Please reference the latest 10WD Library, distributed by DCX Controls Coordinators, for the robot related modules.
AS OF 2/4/2011 43 CUSW REL1.1

ROBOT PROGRAM NAMING
Robot program names shall follow the convention described by the table below:
Table 1. Program Names
Program Name (8 Comment

Style # char. max) (16 char. max) Program Description
Programs
1 STYLE001 Maint Style 1 (Maintenance Program) - User Specified
2 STYLE002 WeldGunForceChck User Specified - Weld Gun Force Check
3 STYLE003 Tip Change (Maintenance Program) - Executes motion and/or macro

calls required to change the tips on the weld gun
4 STYLE004 Purge (Maintenance Program) - Executes motion and/or macro

calls required to purge the dispense gun
5 STYLE005 Tip Burn In (Maintenance Program) - Executes motion and/or macro

calls required to burn in the tips on the weld gun
6 STYLE006 Service Program (Maintenance Program) - Executes motion and/or macro

calls required to move the robot to the service position
7 STYLE007 TipDress 1st Gun / (Maintenance Program) - Executes motion and/or macro
Tip1BurnIN calls required to dress the tips on the 1st gun
8 STYLE008 TipDress 2nd Gun / (Maintenance Program) - Executes motion and/or macro
Tip2BurnIN calls required to dress the tips on the 2nd gun
9 STYLE009 Tool Change (Maintenance Program) - Executes motion and/or macro

calls required to change the tool on the robot
10 - 19 STYLE010 - User Specified User Specified

STYLE019

STYLE029

STYLE039
STYLE049
50 - 63 STYLE050 - User Specified User Specified - Future expansion

STYLE063
AS OF 2/4/2011 44 CUSW REL1.1

ROBOT INTERFERENCE ZONES
Zone Identification Summary/Definitions:
Station / Work Area based zones.
Zones 1, 2& 3:
Station Zones are defined as the area where two or more robots are executing work on or exchanging (transferring) a work piece at a physical
station. Examples of stations are turntables, work fixtures, holding bucks and transfers or shuttles.
Work Area Zones are defined as the area where two or more robots are executing work on or exchanging (transferring) a work piece without
the use of a physical station. Examples of this would be robot to robot hand off by the use of Geo-fector EOAT (End Of Arm Tooling).
Station and Work Area Zones are applied using an non-alternating pattern. For example a robot would pick-up a part in Zone 1 then transfer it
to Zone 2. The next robot would pick-up the part from Zone 1 then transfers it to Zone 2. This non-alternating pattern would continue with
Zone 3 only being required for a robot that needs three Station or Work Area zones.
Transition Zones/Hand-off zones

Zones 4 & 5:
Transition Zones are when two or more robots, working side by side, are needed to move (transition) from one process area to another
process area when a physical interference between the robots is present during the transition. For example welding robots moving from a geo
weld position to a re-spot weld position would require some Transition zone protection.
Hand-off Zones are used for robot to robot hand-off. Hand-off is when one robot loads the work piece from it EOAT directly onto the other
robot‟s EOAT without the use of a station.
Hand-off Zones are applied using an non-alternating pattern. For example a robot would pick-up a part in Zone 4 then transfers it to Zone 5.
The next robot would pick-up the part from Zone 4 then transfers it to Zone 5 etc.
Process Interference Zones / Duty Zones

Zones 6 thru 8:
Process Interference Zones are defined as the zones around the work piece that the robots application is working around. For example two or
more robots might need to cross each others path in order to complete its process on the work piece. In this case these Process Zones would
be used to allow the robots to safely “chase” each other around the work piece.
Duty Zones are defined as other Duties that the process or application requires but are in excess of the previous zone definitions. For
example, gantry robots having a part transfer at a higher elevation then Zones 1-3 could use these zones like a Work Area Zone.
Examples:
Interference Zone Example 1: This example shows Zone 1 and 2 as Station Zones. Zones 4 & 5 are Transition Zones and Zones 6 – 8 as
Process Interference Zones.
Interference Zone Example 2: This example shows Zone 1 and 2 as Work Area Zones. Zone 4 is a hand-off Zone and Zones 6 & 7 are
Process Interference Zones
AS OF 2/4/2011 45 CUSW REL1.1

Interference Zone Example 1
AS OF 2/4/2011 46 CUSW REL1.1

Interference Zone Example 2
The definitions described and show above, are to be followed as described and are not subject to interpretation. If the above definitions can
not be applied to a specific application then approval from a Chrysler Robotics Engineer or Launch Technician will be required to redefine how
Interference Zones are to be used. Reference Pictures Only See Standard Robot Logic Reference for Details.
AS OF 2/4/2011 47 CUSW REL1.1

PLC / ROBOT TIMING DIAGRAMS
New Cycle Start
Robot Inputs
*Hold
Resume
Production Cycle
Fault Reset (2)
Style1-Style64
Option1-Option4
Prod Start (3) (3)
Robot Outputs
RobotInAuto
RobotFaulted-ProcessFault
Robot Ready
Production Cycle
ActiveStyle1-ActiveStyle64
Prg Paused
Prg Running
In Cycle
Option1Active-Option4Active
RobotAtHome
1) Robot is in a starting mode of faulted inbetween cycle

2) Fault Reset can be dropped after seeing Robot Ready go high
3) Style and option bits need to be set before Prod Start is set, Prod Start can be dropped when Prg Running goes high
AS OF 2/4/2011 48 CUSW REL1.1

Stop and Resume from Fault
Robot Inputs
*Hold
Resume (5)
Production Cycle
Production Cycle
Fault Reset
Style1-Style64
Option1-Option4
Prod Start
Robot Outputs
RobotInAuto
(4)
Robot Ready
Production Cycle
Production Cycle
Prg Paused
Prg Running
In Cycle
RobotAtHome
4) Fault occurs and robot sets RobotFaulted and/or Process Fault

5) Resume signal does not require Style Number or Option Bits
AS OF 2/4/2011 49 CUSW REL1.1

Stop and Resume from Hold
Robot Inputs
*Hold (6)
Resume
Production Cycle
Production Cycle
Fault Reset
Style1-Style64
Option1-Option4
Prod Start
Robot Outputs
RobotInAuto
Robot Ready
Production Cycle
Production Cycle
Prg Paused
Prg Running
In Cycle
RobotAtHome
6) When *Hold signal is lost, robot pauses program without faults
AS OF 2/4/2011 50 CUSW REL1.1

REGISTER USAGE
Register names shall be a maximum of 16 characters in length and the name shall reflect the purpose of the register or counter.
NUMERICAL REGISTER USAGE

Numerical Registers are used for storage of Real or Integer values. The table below shows the registers that are reserved.
Table 2. Numerical Registers
Preset
Register Number Register Comment Register Description Value
1 Current Tool ID Current Tool ID
2 Desired Tool ID Desired Tool ID
3 Devnet Status DeviceNet Device Status Check Result
4 DevnetConnRetry DeviceNet Connection Retries 3
5 Current Home Pos Home Position to Return to During Service Macro
6 CurrentFixtureID Current Fixture ID
7 DesiredFixtureID Desired Fixture ID
8 Line Number Line Number
9 Spare
10 SrvGunReserved
11 SrvGunReserved
Reserved for ServoGun Tip Wear and Autotuning
12 SrvGunReserved
13 SrvGunReserved
14 CompletedBurnIns Completed Number Burn Ins
15 RequiredBurnIns Required Number Burn Ins - set by user 3
16 ATISequenceStep Current Step of ATI Sequence
17 ATIRecovery ATI Recovery Method
18 Spare
19 Gun1BurnInSched Gun 1 Weld Schedule for Burn In
20 Gun2BurnInSched Gun 2 Weld Schedule for Burn In
21 Gun1 Spot Count Gun 1 Spot Weld Count
22 Gun1 Tip Dress Gun 1 Tip Dress
23 Gun2 Spot Count Gun 2 Spot Weld Count
24 Gun2 Tip Dress Gun 2 Tip Dress
25 TipWR Cycle CNT Tip Wear Cycle Count
26 TipWR Cycle MAX Tip Wear Max Cycles
27-39 Spare
40 NumWeldRetries Number of Weld Retries 1
41 ColGuardDefault Sensitivity Default Register for Collision Guard 100
42 ColGuardSensitiv Increased Sensitivity Register for Collision Guard 150
43-100 Spare
101 ToolModelNum Temporary Storage of Tool Model Number
Temporary Storage of 1's Digit of Robot/Station
102 1sRobot/StatNum
Number
Temporary Storage of 10's Digit of Robot/Station
103 10sRobot/StatNum
Number
104-129 Spare
130 ISRA Mode Vision Mode

131 ISRA Type Vision Vehicle Type
132 ISRA Subtype Vision Vehicle Sub
133 ISRA Color Vision Vehicle Color
134 ISRA PR Vision Ofset Index
135 ISRA Error Vision Error
136 ISRA Temp Vision Temp
AS OF 2/4/2011 51 CUSW REL1.1

Preset
Register Number Register Comment Register Description Value
137 ISRA Set Nominal ISRA Set Nominal
138 ISRA Vis Pos X ISRA Vis Pos X
139 ISRA Vis Pos Ext ISRA Vis Pos Ext
140 Rack Position Rack Position
141
142 ISRA Menu ANS ISRA Menu ANS
143
144
145 Scratch1 Scratch1
148
149 Part Rapid X Part Rapid X
150 Part Delta X(mm) Part Delta X(mm)
151 0th Part X 0th Part X
152 Calc'd Part X Calc'd Part X
153 Calc'd Part No Calc'd Part No
154 Search 1 Part X POS Search 1 Part X POS
155 Search 2 Part X POS Search 2 Part X POS
156 Search X POS DIF Search X POS DIF
157 Found Part X Found Part X
158 Found Part No Found Part No
159 Part No DIF Part No DIF
160 ForcChkBadMeas
161 ForcChkFailed
162 ForcChk1ShakFail
163 ForcChk2ShakFail
164 ForcChkFShakFail
165 ForcChkPartsRack
There are a total of 200 numerical registers. The user is free to use any other numerical register. The following is an example of using a numerical
register in a teach pendant program.
10: R[1] = 34 ;
11: GO[3] = R[1] ; => Meaning Robot Group Output GO[3] = 34 value
AS OF 2/4/2011 52 CUSW REL1.1

POSITION REGISTER USAGE
The table below shows the position register list to be used on the WD project. Moving to these positions is handled using the appropriate macro listed in
the macro section of this document.
Table 3. Position Registers
Position Register
Number Position Register Comment Position Register Description
1 Home1 Home1
2 Home2 Home2
3 Pounce Position Pounce Position
4 M/H Wait Position M/H Wait for Dropoff Position
5 Service Position Service Position
6 Spare
7 Spare
8 Spare
9 Spare
10 Spare
11 Spare
12 Spare
13 Spare
14 Spare
15 Spare
16 Spare
17 Spare
18 Spare
19 Spare
20
21
22
23 ReservedServoGun Reserved for Servo Gun Autotuning and Tip Wear Operations
24
25
26
27 ReservedSpotTeach Reserved for Servo Gun
28 Spare
29 Spare
30 Spare
31 Pick 1 Position PickUp Position #1
32 Drop 1 Position DropOff Position #1
39
Spare
40 Base Frame Base Frame
41 WK Low Lt Frame WK Low Lt Frame
42 WK Low Rt Frame WK Low Rt Frame
43 WK Up Lt Frame WK Up Lt Frame
44 WK Up Rt Frame WK Up Rt Frame
45 WD Low Lt Frame WD Low Lt Frame
46 WD Low Rt Frame WD Low Rt Frame
47 WD Up Lt Frame WD Up Lt Frame
48 WD Up Rt Frame WD Up Rt Frame
AS OF 2/4/2011 53 CUSW REL1.1

Position Register
Number Position Register Comment Position Register Description
49 Current Position Current Position
50 Offs Base Frame Offs Base Frame
51 Above Pick Above Pick
52 Spare
53 Spare
54 ISRA Vis Pos ISRA Vis Pos
55 WK Nom Vis Pos WK Nom Vis Pos
56 WD Nom Vis Pos WD Nom Vis Pos
57 Rack Nom Vis Pos Rack Nom Vis Pos
58 ISRA CAM1 CALPOS ISRA CAM1 CALPOS
59 ISRA CAM2 CALPOS ISRA CAM2 CALPOS
60 - 89
Spares
90 TCP Target Position
98 Payload ID Position Starting Position to Start Payload ID
99 ZERO Position Robot Zero Mastering Position
100 Spare
101 Nest 1 Drop Position where the tool changer decouples tool 1.
105 Spare
106 Nest 1 Pick Position where the tool changer couples tool 1.
110 Spare
111 Tool Offset 1 Offset used for approach and retreat positions of the robot during the
drop sequence.
drop sequence.
drop sequence.
drop sequence.
drop sequence.
drop sequence.
drop sequence.
drop sequence.
119-200 Spares
Note 1: The robot must be able to move between the different Home positions in a single move without causing damage to the robot, dressout, or
tooling.
Note 2: Only use multiple home positions when performing a Change-out robot program (tool changer application). If no tool change application, the
preferred method is only one home position, unless if a cycle time issue comes up.
AS OF 2/4/2011 54 CUSW REL1.1

USER ALARMS
User Alarms are used to post an alarm and fault the robot from within a teach pendant program or macro.
The table below shows the user alarms that are used for the WD project.
Table 4. User Alarms
User Alarm
Number User Alarm Comment User Alarm Description
1 ToolNotPresent No tool present
2 Invalid Tool Requested Invalid tool requested for pick
3 Unexpected Tool Present Unexpected tool present for drop
4 Tool Nest not Empty Tool nest is not empty, can not drop tool
5 Tool Nest is Empty No tool in nest, can not pick tool
6 DNetPower Not On Apply DNet power
7 Aux Power Not On Apply aux power
8 ReadyToLock1 Not On Tool not positioned properly
9 ReadyToLock2 Not On Tool not positioned properly
10 ToolStndIntlk1 Not On TSI limit switch fault
11 ToolStndIntlk2 Not On TSI limit switch fault
12 RTL Sensor State Mismatch RTL sensor states don't match
13 TSIV Sensor State Mismatch TSIV sensor states don't match
14 Latch Overload/Short Circuit Short circuit or overload on latch solenoid output
15 Unlatch Overload/ShortCircuit Short circuit or overload on unlatch solenoid output
16 Spare Overload/Short Circuit Short circuit or overload on spare solenoid output
17 RTLV / RTL Mismatch Mismatch condition between RTLV and RTL inputs
18 TSRV / TSIV Mismatch Mismatch condition between TSIV and TSRV inputs
19 UnsafeUnlatch Unlatch command received resulting in an unsafe tool release and
therefore was not processed.
20 LckUnlckSensFlt-Both High Locked and Unlock inputs high at same time
21 LatchNotComplt-Latch Timeout Timeout on locked input after latch command
22 UnltchNtComplt-UnlatchTimeout Timeout on unlocked input after unlatch command
23 TSIVFault-Switch Failed High Failure of TSIV limit switch(es) in high position
24 RTLFault-Switch Failed High Failure of RTL sensor(s) in high position
25 CommError-Master to Tool Communication error between master and tool modules
26 LckOrUnlckSensIncorrectState Lock or Unlock Sensor in Incorrect State - Possible Failed Sensor
27 - 79 Spare
80 ISRA: Reset Errors Timeout ISRA: Reset Errors Timeout

81 ISRA: Change Auto/Ready Prep ISRA: Change Auto/Ready Prep
82 ISRA: Change Auto Handshake ISRA: Change Auto Handshake
83 ISRA: Ready Prep Timeout ISRA: Ready Prep Timeout
84 ISRA: Meas Data OK Timeout ISRA: Meas Data OK Timeout
85 ISRA: Result Transfer ON ISRA: Result Transfer ON
86 ISRA: Result Transfer OFF ISRA: Result Transfer OFF
87 ISRA: Meas Still Running ISRA: Meas Still Running
88 ISRA: Wrong Op Mode Entered ISRA: Wrong Op Mode Entered
89
90 ISRA: Err Setting Meas Data ISRA: Err Setting Meas Data
91 ISRA: Err Starting Meas ISRA: Err Starting Meas
92 ISRA: Features/Tol Error ISRA: Features/Tol Error
93 ISRA: Measurement Error ISRA: Measurement Error
94
95 ISRA: Rack NOT OK ISRA: Rack NOT OK
There are a total of 50 user alarms. The user is free to use any other user alarm. The following is an example of using a user alarm in a teach pendant
program.
10: UALM[1] ;
11: UALM[4] ;
AS OF 2/4/2011 55 CUSW REL1.1
REFERENCE POSITION USAGE
Reference Positions are global positions that can set an output automatically when the robot encoder values indicate that the robot is at the position.
This automatic checking is done where the robot is jogged to a position or moved via a macro or program.
The table below shows the reference positions to be used on the WD project.
Table 5. Reference Positions
Reference Position
Number Position Name At Position Digital Output
1 Home1 27
2 Home2 User Specified
3 - 10 Spare User Specified
11 RobotAtUserPos1 66
23 UnCouple Tool Position 1 646
Note 1: The robot must be able to move between the different Home positions in a single move without causing damage to the robot, dressout, or
tooling.
Note 2: Only use multiple home positions when performing a Change-out robot program (tool changer application). If no tool change application, the
preferred method is only one home position, unless if a cycle time issue comes up.
Note 3: Housekeeping macros (HOME_IO) are run when the robot is in range of a reference position set as a valid home position. Reference Position
#1 must be set as a valid home position to execute HOME_IO after normal program execution. HOME_IO execution follows normal program execution
when a robot is moved from a non home position to a valid home position.
AS OF 2/4/2011 56 CUSW REL1.1

INTERCONNECTS
The I/O Interconnect feature allows the robot to output the states of digital inputs to notify external devices of the state of those inputs. The interconnect
tables displays the inputs that are mapped to outputs. For example, per the configuration in the table below if DI[95] was to turn on, the robot would
then turn on DO[416]. If DI[95] then turns off, DO[416] also turns off.
I/O is interconnected based on the configuration of the robot. For example, a material handling robot would have Input 513 interconnected to Output 77.
It would not have Input 204 interconnected to Output 102 because these I/O points are used for spot welding robots.
The table below shows the interconnects that are used for the WD project.
Table 6. Interconnects
Input (DI) Description Output (DO) Description

113 External1StartRequest 402 Dispense1RemoteStart
115 External2StartRequest 466 Dispense2RemoteStart
204 W1SteppersReset 102 StepperReset1Ack
236 W2SteppersReset 103 StepperReset1Ack
208 W1DressTipsRequest 100 TipDressRequest1
240 W2DressTipsRequest 48 TipDressRequest2
203 W1WeldInProgress 32 WeldInProgressActive1
235 W2WeldInProgress 47 WeldInProgressActive2
385 Dispense1DispenserReady 95 Dispense1DispenserReady
390 Dispense1RemoteStartInProgress 114 ExternalStart1InProgress
449 Dispense2DispenserReady 96 Dispense2DispenserReady
454 Dispense2RemoteStartInProgress 115 ExternalStart2InProgress
513 Part1Present 77 RobotPartPresent1
AS OF 2/4/2011 57 CUSW REL1.1

MACROS
Macro programs can be run standalone, but are intended to be used as subroutines which are called from the main style program. Defining a program
as a macro program is done by setting the program type to “Macro” in the program header.
When these programs are called from a main style program, the program pointer jumps to the subroutine. Similarly, when the subroutine is complete,
the program pointer jumps back to the next line in the main style program.
Macro programs can be set to either prohibit or allow robot motion statements. When motion statements are prohibited, the macro program can be
manually executed while a robot fault is active. Therefore, it is recommended that macro programs that only execute I/O signals be set to prohibit
motion statements (i.e. open/close gripper macro programs). Prohibiting motion statements in a macro program is done by setting all available motion
groups to “*” in the program header. Allowing motion statements in a macro program is done by setting the appropriate motion groups to “1”.
The user is free to place additional macros into the macro table provided they do not take up a position reserved by the macro table listed below.
FANUC Spottool+ standard macros such as tip wear compensation are not called out in the macro table. These macros are automatically loaded on the
robot at time of software load.
Table 7. Macros
Macro Table Macro Name Macro Comment

Position (8 Char. Max) (16 Char. Max) Macro Description
Macros
1 HOME_IO Setup Outputs Handles I/O for start of next cycle (housekeeping)
MF 1
APP_IO SetApplicationIO Setup all application specific inputs and outputs
ATI_CHCK Check ATI Errors Handles ATI errors experienced during the tool pick and
tool drop processes
CHK_TOOL Check Tool Checks for the correct tool on the wrist
ENTRZON1 Enter Zone 1 Handles IO for zone entering
MOV_HOME Move to Home Executes motion to move the robot home from the
current position
MVHMPNCE MoveHomeFromPnce Executes motion to move the robot home from the
pounce position
NST1DROP Drop Tool Nest 1 Executes motion and/or macro calls required to drop tool
1 in nest 1
2 in nest 2
3 in nest 3
4 in nest 4
AS OF 2/4/2011 58 CUSW REL1.1

Macro Table Macro Name Macro Comment
Position (8 Char. Max) (16 Char. Max) Macro Description
NST1PICK Pick Tool Nest 1 Executes motion and/or macro calls required to pick tool
1 from nest 1
2 from nest 2
3 from nest 3
4 from nest 4
PED_DISP Ped Dispense Executes motion and/or macro calls required to perform
dispensing with a pedestal mounted gun
PED_SPOT Ped Spot Weld Executes motion and/or macro calls required to perform
spot welding with a pedestal mounted weld gun
PED_STUD Ped Stud Weld Executes motion and/or macro calls required to perform
stud welding with a pedestal mounted gun
PREPDROP Tool Drop Prep Executes motion and/or macro calls required to prepare
to drop the tool on the wrist in its nest
PREPPICK Tool Pick Prep Executes motion and/or macro calls required to prepare
to pick a tool from its nest
PRGPDGN1 Purge Ped Gun 1 Executes motion and/or macro calls required to perform a
purge on pedestal mounted dispense gun 1
RST_STPR Reset Stepper Handles IO for resetting the spot weld stepper motor
TPBURNIN Tip Burn In Executes motion and/or macro calls required to perform a
tip burn in on a servo weld gun
TPCHNGPD TipChangePedGun Executes motion and/or macro calls required to perform a
tip change on a pedestal mounted weld gun
TPDRSPD TipDressPedGun Executes motion and/or macro calls required to perform a
tip dress with a pedestal mount weld gun
TPDRSGN1 DressCarriedGun1 Executes motion and/or macro calls required to perform a
tip dress on carried weld gun 1
TPDRSGN2 DressCarriedGun2 Executes motion and/or macro calls required to perform a
tip dress on carried weld gun 2
10 - 11 Reserved for SpotTool+
18 Reserved for SpotTool+
AS OF 2/4/2011 59 CUSW REL1.1

FLOW CHART EXAMPLES
Contained in the following pages are flow charts of the processes required for the WD program. The information contained in each section is for
REFERENCE ONLY.
Flow Chart Legend

Process: Logic statement
Data: Data/Input from an

external device is required to
process this step‟s logic
Decision: Logic decision
Move: Servo movement called

in logic
Connector: Off Page
Connector: On Page
AS OF 2/4/2011 60 CUSW REL1.1

Material Handling
Start
Set Robot Payload, Tool

Frame, and User Frame
Setup Application Specific
I/O (Macro)
Acknowledge Style GO[1]
Reset Collision Guard

Sensitivity to Default R[41]
Tool Changer Applications Only

No Tool
Changer
Set Desired Tool ID R[2]
Check Tool (Macro)
Set MH Gripper (if

necessary) (Macro)
Set additional
gripper states (if A
necessary) (Macro)
Move to Pounce
Wait for go to
Pickup 1 DI[49]
Set at Pounce DO[25]
Reset Clear of Pickup 1

DO[49]
Reset DO[89] Reset Clear to Transfer
Reset DO[94] DO[31]
Verify Part not

Present (Macro) Zone Check (if
necessary) (Macro)
Open the Gripper

and Verify Open
Move Over
(Macro)
Pickup 1
Go to Work or Return Home Verify Tool is

Move Home from
Return Home DI[25] Pounce
Correct (Macro)
From
(call Macro)
Pounce?
Verify Part not
Go To Work DI[31] Present (Macro)
End
Set Robot at Work DO[18]
Reset Robot at Pounce B

DO[25]
AS OF 2/4/2011 61 CUSW REL1.1

Material Handling (cont’d)
Open the Gripper

and Verify Open
(Macro)
Note: Collision Guard
sensitivity increased prior
Set Collision Guard to moving into tooling to
Sensitivity R[42] help prevent damage if a
collision occurs
Move to Pickup 1 Note: Set reposition

tooling handshake may
be required either before
or after gripper is closed
Check for Part
Present (Macro)
Note: Receiving robot or

Note: Material Handling fixture will always set the
functions may require Set Reposition Tooling GO[2] Reposition Tooling bit to
process recovery. Refer the delivering robot or
to the MH process fixture
recovery section. Wait for Tooling
Repositioned
GI[5] Note: Reposition Tooling
bits only required when
Robot to Robot/Fixture
handshaking is needed
Close the gripper and verify
closed (Macro)
Set At Pickup 1 DO[50]
Select Robot Payload with

Part
Note: Validate open Wait for Tooling

before moving Repositioned
GI[5]
Reset Reposition Tooling

GO[2]
Move Clear of Note: This robot

Fixture Part movement must be
Presence of “FINE” type
Wait for Exit

Pickup 1 DI[50] Note: Lessons learned,
PLC is looking for a part
in the robot gripper and
has not been dropped
Check for Part

Present (if
necessary) (Macro)
AS OF 2/4/2011 62 CUSW REL1.1

Reset at Pickup 1 DO[50]
Move Clear of
Pickup 1
Set Clear of Pickup 1 DO[49]
Set Clear to Transfer DO[31]
Set Clear of Interference

Zone (if necessary) DO[33]
Move
Process Applications
(as required)
Dispense
Inspection
Spot Weld
Stud Weld
Wait for go to
Dropoff 1 DI[51]
Zone Check (if

necessary) (Macro)
Reset Clear of Dropoff 1

DO[51]
Reset Clear to Transfer
DO[31]
Move Over
Dropoff 1
Verify Tool is
Correct (Macro)
Set Collision Guard

Sensitivity R[42]
Move to Dropoff
1
Set at Dropoff 1 DO[52]
AS OF 2/4/2011 63 CUSW REL1.1

D
Note: Receiving robot or
fixture will always set the
Reposition Tooling bit to
Wait for the delivering robot or
Reposition fixture
Tooling GI[5]
Note: Reposition Tooling
bits only required when
Open the Gripper (Macro) Robot to Robot/Fixture
Select Payload without handshaking is needed
Part(s), Tool Frame and User
Frame
Note: Material Handling Set Tooling Repositioned
functions may require GO[2]
process recovery. Refer
to the MH process Note: Assumes robot
recovery section. Move Clear of drops part to fixture
Robot Part
Present
Note: This robot
movement must be
Verify Parts Not of “FINE” type.
Present
(Macro)
Wait for Exit

Dropoff 1 DI[52]
(if necessary)

Reset at Dropoff 1 DO[52]
Reset Tooling Repositioned

GO[2]
Move Clear of
Dropoff 1
Set Clear of Dropoff 1

DO[51]
Set Clear of Interference
Zone (if necessary) DO[33]
E
Move Clear of
Transfer
Set Work Complete DO[19]
Set Clear to Transfer DO[31]

Wait for Work
Reset Robot at Work DO[18] Complete Ack.
DI[32]
Move Home
(Macro) Reset Work Complete DO[19]
E End
AS OF 2/4/2011 64 CUSW REL1.1

Abort Pick/Abort Override Example

(if required)
From Standard Material

Handling Process
Note: Abort outputs are MH Function Macro

automatically set when (Ex: Check Part
the user selects a Present)
designated recovery
option during standard
material handling fault
recovery (DO[89,94]). Abort Pick or
Abort Over Ride Yes
The user must manually
reset these outputs when Requested?
the recovery process is DO[89,94]
complete.
No User Specified Macro
(Ex: Abort Pick)
Continue Standard Material Jump to Program Label
Handling Process (Ex: End Program)
AS OF 2/4/2011 65 CUSW REL1.1

Dispense
Start
A

Frame, and User Frame Reset Dispense Style
Setup Application Specific GO[31]
I/O (Macro) Reset Dispense Style Strobe
Note: Collision Guard DO[394]
Acknowledge Style GO[1] sensitivity increased prior
to moving into tooling to Set Collision Guard
Reset Collision Guard Sensitivity R[42]
Sensitivity to Default R[41] help prevent damage if a
collision occurs
DO[31] Move To Seal
Start and Turn
on Gun
Move to Pounce Note: The Nordson

controller requires approx Move Along Path
500ms between the final
gun off command and
Set at Pounce DO[25] setting dispense
complete. Therefore a Move To Seal
move clear of part is End and Turn off
performed between these Gun
Go to Work or commands to allow this
Return Home Return Home time to elapse.
From DI[25] Move Clear of
Pounce? Part
Move Home from
Pounce (Macro)
Go To Work DI[31] Reset Collision Guard
Sensitivity R[41]
Set Dispense Complete
Reset Robot at Pounce DO[25] End
DO[401]
Zone Check (if Wait for Dispense

necessary) (Macro) Vol. OK
Pre-processing for Dispense Reset Dispense Complete

Equipment DO[401]
Reset Dispense Robot in
Process DO[393]
Wait for
Dispenser Ready Post-processing for
DI[385] Dispense Equipment
Set Dispense Robot in Note: The Nordson Move Home

Process DO[393] controller requires 100ms (Macro)
Wait 100ms delay time between
setting robot in process,
Set Dispense Style GO[31] dispense style, and Set Work Complete DO[19]
Wait 100ms dispense style strobe.
Wait statements are used Set Clear to Transfer DO[31]
Set Dispense Style Strobe here to allow the Nordson
DO[394] to see the delay. Set Clear of Zone DO[33]
Wait for
Dispense In Wait for Work
Process DI[386] Complete Ack.
DI[32]
A End Reset Work Complete DO[19]
AS OF 2/4/2011 66 CUSW REL1.1

Spot Welding
Start

I/O (Macro)

DO[31]
Move to Pounce
Return Home
Go to Work or
Return Home DI[25] Move Home from
From Pounce (Macro)
Pounce?
Go To Work DI[31]
End
Reset Robot at Pounce DO[25]
Zone Check (if

necessary) (Macro)
Move To Weld 1
Select Schedule, Weld 1
Move To Weld 2
Move Clear of
Clamps
AS OF 2/4/2011 67 CUSW REL1.1

Spot Welding (cont’d)
Set Clear to Unclamp Early

DO[65]
Tip Dress Tip Dress DI[28]

or Return
Home?
Move Home
Move Clear of Robot at User Position bit
Move Home Transfer/To Tip will be set by reference
(Macro) Dress position configuration. This
allows the PLC to
acknowledge work
Set Work Complete DO[19] Set Work Complete DO[19] complete.
Set Clear to Transfer DO[31] Set Clear to Transfer DO[31]
Set Clear of Zone DO[33] Set Clear of Zone DO[33]
Wait for Work Wait for Work

Complete Ack. Complete Ack.
DI[32] DI[32]
Reset Work Complete DO[19] Reset Work Complete DO[19]

Note: Tip Dress Macros
use an argument call for
the burn in schedule.
Tip Dress – (Macro)
Schedule 0 skips the burn
in.
Move Home
(Macro)
End
AS OF 2/4/2011 68 CUSW REL1.1

Stud Welding
Start
A

Frame, and User Frame Set Clear to Unclamp Early
Setup Application Specific DO[65]
I/O (Macro)

Move Home
Reset Clear to Transfer (Macro)
DO[31]
Set Work Complete DO[19]

Move to Pounce Set Clear to Transfer DO[31]
Set Clear of Zone DO[33]

Wait for Work
Complete Ack.
Return Home DI[32]
Go to Work or
Return Home DI[25] Move Home from
From Pounce (Macro)
Reset Work Complete DO[19]
Pounce?
Go To Work DI[31]
End End
Reset Robot at Pounce DO[25]
Zone Check (if

necessary) (Macro)
Move To Weld 1
Move To Weld 2
Move Clear of
Clamps
AS OF 2/4/2011 69 CUSW REL1.1

Tip Change (Style #3)
Start

I/O (Macro)
Move Dress
Approach (if
necessary)
Note: A tip dress is Do Tip Dress Gun 1 – Note: Tip Dress Macros
performed prior to cap Schedule 0 (Macro) use an argument call for
change to allow operator DELAY for TipDress the burn in schedule.
to verify tip dresser is Complete (wait 1.0 sec) Schedule 0 skips the burn
properly dressing caps. in.
Reset Tip Dress Complete
DO[29]
Move to Tip
Change Position
Note: 4.0 sec puls

Pulse W 1 W ater Off DO[587] required to allow the
watersaver to turn OFF
and Blead down.
W ait W 1OKToW eld DI[785]=OFF

AND W 1ValveClosed DI[786]=ON
Set Robot at Service DO[26] Reset Robot at Service DO[26]
Set Ready for Tip Change Reset Ready for Tip Change
DO[30] DO[30]
Reset Stepper (Macro)
W ait for Service Seat Caps Gun 1 (Macro)

Complete DI[26]
Note: Tip wear compensation
Do Tip W ear Compensation
to be performed without
Gun 1 (Macro)
measurement error checking.
Move Dress
Approach (if
necessary)
Pulse W 1 Reset W ater Saver

DO[586] Note: Tip dress macros
perform burn in and wear
compensation after dress.
W ait W 1OKtoW eld Refer to macros for
DI[785]=ON details.
Do Tip Dress Gun 1 –

(Macro)
Move Home
End
(Macro)
AS OF 2/4/2011 70 CUSW REL1.1

Purge (Style #4)
Start

I/O (Macro)
Set Ext Purge 1 in Progress

DO[97]
Pre-processing for Dispense
Equipment
Set Dispense 1 Purge
DO[416]
Wait „X‟ Seconds
Reset Dispense 1 Purge

DO[416]
Post-processing for
Dispense Equipment
Reset Ext Purge 1 in
Progress DO[97]
Note: Home IO may
need to be manually Home IO (if necessary)
initiated if the style (Macro)
program does not have
any robot motion.
End
AS OF 2/4/2011 71 CUSW REL1.1

Tip Burn In (Style #5)
Start

I/O (Macro)
Move to Service
Position (if
necessary)
Tip Burn In (Macro)
Move Home
(Macro) (if
necessary)
Home IO
(Macro) (if
necessary)
End
AS OF 2/4/2011 72 CUSW REL1.1

Service (Style #6)
Start

I/O (Macro)
Move to Service
Position
Set Robot at Service DO[26]
Wait for Service

Complete Req.
DI[26]
Reset Robot at Service DO[26]
Move Home
(Macro)
End
AS OF 2/4/2011 73 CUSW REL1.1

Tip Dress Gun 1 (Style #7)
Start

I/O (Macro)
Approach Move
(if necessary)
Note: Tip Dress Macros Note: Tip dress macros

use an argument call for perform burn in and wear
the burn in schedule. Tip Dress Gun 1 – (Macro) compensation after dress.
Schedule 0 skips the burn Refer to macros for
in. details.
Move Home
(Macro)
End
AS OF 2/4/2011 74 CUSW REL1.1

Start

I/O (Macro)
Approach Move
(if necessary)
Note: Tip Dress Macros Note: Tip dress macros

use an argument call for perform burn in and wear
Tip Dress Gun 2 – (Macro)
the burn in schedule. compensation after dress.
Schedule 0 skips the burn Refer to macros for
in. details.
Move Home
(Macro)
End
AS OF 2/4/2011 75 CUSW REL1.1

Tool Change (Style #9)
Start

I/O (Macro)
Set Desired Tool ID GI[41]
Check Tool (Macro)
Move Home
(Macro)
End
AS OF 2/4/2011 76 CUSW REL1.1

Set Application IO (Macro)
Start
Set Application Specific IO
End
AS OF 2/4/2011 77 CUSW REL1.1

Check ATI Errors (Macro)
Start
A
Select Current Sequence Sequence List AR[1]:

AR[1] A. Ready to Pick/Latch/Unlatch
Set ATI Recovery Method B. Ready to Latch
R[17] C. Exit Pick/Ready to Drop/Exit Drop
D. Ready to Unlatch
No ATI Error
Present?
Yes
End
Post User Alarm for ATI Error
and Pause Program
R[17]=1 Select R[17]=0

Recovery
Method R[17]
Reset Latch Tool DO[632] Set Clear Errors DO[635]
Reset Unlatch Tool DO[633] Wait „x‟ seconds for ATI to

reset
Set Clear Errors DO[635]
Reset Clear Errors DO[635]
Wait „x‟ seconds for ATI to
reset
Reset Clear Errors DO[635]

A
End
Note: This recovery method

will retry the latch or unlatch
operation in the pick or drop
macro upon exiting.
AS OF 2/4/2011 78 CUSW REL1.1

Check Tool (Macro)
Start
Set Tool ID R[1], Line

Number R[8], and Tool ID for
PLC GO[3]
Does Current
Yes Tool ID Match
Desired Tool
ID?
End No
Is Tool on
No
Wrist? DI[644]
R[1]
Yes Pick Preparation and Pick

Tool (Macro)
Drop Preparation and Drop

Tool (Macro)
AS OF 2/4/2011 79 CUSW REL1.1

Drop Tool Nest 1 (Macro)
Start
Set Request to Enter Tool
Nest DO[71]
Set Robot UTOOL and

UFRAME Wait for Clear to
Enter Tool Nest
DI[81]
Clear ATI Errors
DO[635]
Reset Clear of Tool Nest
DO[72]
Reset Request to Enter Tool
Nest DO[71]
Set Tool Device Offline

(Macro)
Note: (if applicable) Tool nest

1 approach and retreat
positions are to use the same Move to Tool
position as the couple position, Nest Perch
PR[6]. This position is then
offset by a distance using a
tool offset via position register,
PR[14].
ATI General Yes
Error DO[645]
High?
No ATI State Check – Sequence

5 (Macro)
Note: Turn Out of Nest off
before TSIV switches are
made.
When the Out of Nest Output is Reset Out of Nest DO[637]

set high, the tool changer
globally disables the unlatch
command. This output must Move to Tool
be turned off to unlatch the tool Nest
changer.
Wait for Tool in

Nest 1 DI[73]
ATI State Check – Sequence

6 (Macro)
AS OF 2/4/2011 80 CUSW REL1.1

Drop Tool Nest 1 (cont’d)
Note:
In the robot ladder logic, PMC the following logic is A
added: (Even if you ONLY have one tool, you must
define a Reference Position (below) in order to
UnCouple a tool.)
IF DO[646:UnCoupleToolPos1]=ON ReferncePos[11] Note: You do NOT need to set

or DO[647:UnCoupleToolPos2]=ON ReferncePos[12] Reset Latch Tool DO[632] this DO[654] output in robot
or DO[648:UnCoupleToolPos3]=ON ReferncePos[13] TP, this will be handled in
or DO[649:UnCoupleToolPos4]=ON ReferncePos[14] Set Unlatch Tool DO[633] robot code. It is FYI for you.
or DO[650:UnCoupleToolPos5]=ON ReferncePos[15]
or DO[651:UnCoupleToolPos6]=ON ReferncePos[16] RbtOKtoUnCouple DO[654]
THEN
Unlatch
turn DO[RbtOKtoUnCouple]=ON
DI[633] High?
Code in KAREL to Unlock:
IF (DO[637] = OFF) AND (DO[633]+) AND Yes No - Timeout
(DO[654]=ON)
THEN DO[633]=ON
ATI Unlatched General Error DO[645]
or General
Error?
Tool Unlocked DI[633] ATI State Check – Sequence

7 (Macro)
Not Tool Locked DI[632]

Set Robot Payload without
Tool
positions are to use the same
position as the couple position, Set Robot UTOOL and
PR[6]. This position is then UFRAME
PR[14]. Move Clear of
Tool in Nest
This move must be 1 inch Inputs
further than complete
separation of the tool and be Note: Check for
of “FINE” type disengagement of
Wait for Tool in tool changer
Nest 1 DI[73]
ATI General Yes ATI State Check – Sequence

Error DO[645]
8 (Macro)
High?
No
Wait for Tool in
Nest 1 DI[73]
Move 4 Inches
Above Clear of
Tool in Nest
Reset Unlatch Tool DO[633]
Set Out of Nest DO[637]
Clear ATI Errors

DO[635]
Set Robot UTOOL and
UFRAME
Move Clear of
End
Tool Nest
AS OF 2/4/2011 81 CUSW REL1.1

Enter Zone 1 (Macro)
Start
Reset Clear of Zone 1

DO[33]
W ait for OK to
Enter Zone 1
DI[33]
End
Home IO (Macro)
Start
Set Housekeeping Outputs
End
Move Home (Macro)
Start
NOTE: Get_Home Karel

Call Get_HOME (Karel Program) program will copy the position
taught in Reference position to
PR[Home]
NOTE: Fine Move Required

Move Home
End
Move Home From Pounce (Macro)

Start
Move Home
From Pounce
End
AS OF 2/4/2011 82 CUSW REL1.1

Pick Tool Nest 1 (Macro)
Start
Clear ATI Errors

Set Robot UTOOL and DO[635]
UFRAME
Set Request to Enter Tool

Move to Tool Nest DO[71]
Nest Perch
Wait for Clear to

Enter Tool Nest
DI[81]
Reset Clear of Tool Nest

DO[72]
Reset Request to Enter Tool
Nest DO[71]
position as the couple position, Move to Tool Note: Turn Out of Nest off
PR[6]. This position is then Nest Approach before TSI switches are made.
tool offset via position register, When the Out of Nest Output is
PR[10]. set high, the tool changer
Reset Out of Nest DO[637]
globally disables the unlatch
command. This output must
be turned off to unlatch the tool
changer.
No Tool Locked
and Tool
Unlocked
Low?
User Alarm – Lock or Unlock
Sensor Incorrect State
Yes
Reset Latch Tool DO[632]
Set Unlatch Tool DO[633]
Unlatch
DI[633] High?
Yes No - Timeout ATI Unlatched General Error DO[645]

or Error
Posted?
Tool Unlocked ATI State Check – Sequence

1 (Macro)
DI[633]
Move to Tool
Nest

2 (Macro)
AS OF 2/4/2011 83 CUSW REL1.1

Pick Tool Nest 1 (cont’d)
Reset Unlatch Tool DO[633]
Set Latch Tool DO[632]
Set Tool Device Online

(Macro)
Latch DI[632]
High?
Yes No - Timeout
ATI Latched General Error DO[645]
or Error
Posted?
Tool Locked DI[632] ATI State Check – Sequence

Not Tool Unlocked DI[633] 3 (Macro)
Set Robot Payload with Tool
Set Robot UTOOL and

UFRAME
Is Tool ID No
correct?
Note: (if applicable) Tool nest User Alarm – Unexpected

1 approach and retreat Yes Tool Present
position as the couple position, Move Clear of
PR[6]. This position is then Tool in Nest
offset by a distance using a Inputs End
PR[10].
ATI General Yes
Error DO[645]
High?
No 4 (Macro)
Move Clear of
Tool Nest Set Out Of Nest DO[637]
Set Robot UTOOL and Set Tool Device Online

UFRAME (Macro)
No
Move Clear of Check Device
Tool Nest Online End
Yes
AS OF 2/4/2011 84 CUSW REL1.1

Process Application Macros (Spot, Dispense, Stud)
MH Ped Spot Weld

Start
Move To Weld 1
Move To Weld 2
Move Clear of
Ped Welder
Tip Dress, Tip

Change, Burn
In, Service or
Go To
Dropoff?
Tip Change Tip Burn In
DI[105] Dropoff 1 DI[104]
Tip Dress Ped Gun – DI[51] Tip Burn In (Macro)
Schedule 0 (Macro)
Reset Tip Dress Complete
DO[29]
Tip Dress
Tip Change Ped Gun DI[28]
(Macro)
Tip Dress Ped Gun –
Tip Dress Ped Gun – End
Schedule 62 (Macro)
Schedule 58 (Macro)
Note: A tip dress is

performed prior to tip
Note: Refer to flow charts Service Request DI[27]
change to allow operator
for tip change and tip to verify tip dresser is
dress macro details MH Service with Part –
properly dressing caps.
(Macro)
Note: Tip Dress Macros

use an argument call for
the burn in schedule.
Schedule 0 skips the burn
in.
AS OF 2/4/2011 85 CUSW REL1.1

Process Application Macros (cont’d)
MH Ped Dispense
Start
A

Equipment Wait for
Dispense Vol.
OK
Wait for
Dispenser Ready
DI[385] Reset Dispense Complete
DO[401]
Note: The Nordson Reset Dispense Robot in

Set Dispense Robot in Process DO[393]
controller requires 100ms
Process DO[393]
delay time between Post-processing for
Wait 100ms setting robot in process, Dispense Equipment
Set Dispense Style GO[31] dispense style, and
dispense style strobe.
Wait 100ms Wait statements are used
Set Dispense Style Strobe here to allow the Nordson
DO[394] to see the delay.
Wait for
Dispense In
Process DI[386] Purge or Go
Purge Gun 1 To Dropoff?
DI[95]
Reset Dispense Style Dropoff 1
GO[31] Purge Ped Gun 1 (Macro)
DI[51]
Reset Dispense Style Strobe
DO[394]
Set Collision Guard End
Sensitivity R[42]
Move To Seal
Start and Turn
on Gun
Move Along Path
Move To Seal
End and Turn off
Gun Note: The Nordson
controller requires approx
500ms between the final
gun off command and
Move Clear of
setting dispense complete.
Nozzle
Therefore a move clear of
part is performed between
these commands to allow
Reset Collision Guard this time to elapse.
Sensitivity R[41]
Set Dispense Complete
DO[401]
AS OF 2/4/2011 86 CUSW REL1.1

Process Application Macros (cont’d)
MH Ped Stud Weld

Start
Move To Weld 1
Move To Weld 2
Move Clear of
Ped Welder
End
AS OF 2/4/2011 87 CUSW REL1.1

Purge Ped Gun (Macro)
Start
Set Ext Purge 1 in Progress

DO[97]
Equipment
Set Dispense 1 Purge
DO[416]
Wait „X‟ Seconds
Reset Dispense 1 Purge

DO[416]
Post-processing for
Dispense Equipment
Reset Ext Purge 1 in
Progress DO[97]
End

Start
Set W1 Reset Stepper DO[590]
Wait for Stepper

Reset DI[204]
Reset W1 Reset Stepper

DO[590]
End
AS OF 2/4/2011 88 CUSW REL1.1

Tip Burn In (Macro)
Start
Reset Register for Burn Ins

Complete R[14]
Do Tip Burn In
Weld Schedule
62
Completed # Note: Number of required

of Burn In‟s burn in‟s to be set by user
Required? No via register value 15.
Yes
Do Tip Wear Compensation Note: Tip wear compensation
Gun 1 (Macro) to be performed without
Set Tip Burn In Complete measurement error checking.
DO[104]
End
AS OF 2/4/2011 89 CUSW REL1.1

Tip Change Ped Gun (Macro)
Start
Pulse W1 Water Off DO[587]
Set Robot at Service DO[26]
Set Ready for Tip Change

DO[30]
Wait for Service

Complete DI[26]
Reset Robot at Service DO[26]
Reset Ready for Tip Change

DO[30]
Seat Caps Gun 1 (Macro)
Do Tip Wear Compensation

Gun 1 (Macro)
Pulse W1 Reset Water Saver
DO[586]
End
AS OF 2/4/2011 90 CUSW REL1.1

Tip Dress Gun 1 (Macro)
Start
Setup Gun 1 Burn in

Schedule R[19]
Set Robot in Tip Dress DO[28]
Move Common
Dress Approach
Set Turn on Tip Dresser

DO[101]
Wait for Tip

Dress Motor On
DI[101]
Move To Dresser
Do Tip Dress
Weld Schedule
60
Move Away from

Dress
Reset Turn On Tip Dresser

DO[101]
No Tip Burn In
Required
R[19]
Yes
Do Tip Burn In Note: Tip burn in and wear
Weld Schedule compensation can be
R[19] skipped. This is to be used
only prior to tip change when
burn in and wear
Do Tip Wear Compensation compensation is not required
Gun 1 (Macro) after a tip dress.

Reset Tip Dress Request 1
DO[100]
[PR Home – Fine Move]
Set Tip Dress Complete DO[29]
Reset Robot in Tip Dress

DO[28]
End
AS OF 2/4/2011 91 CUSW REL1.1

Start
Setup Gun 1 Burn in

Schedule R[20]
Set Robot in Tip Dress DO[28]
Move Common
Dress Approach
Set Turn on Tip Dresser

DO[101]
Wait for Tip

Dress Motor On
DI[101]
Move To Dresser
Do Tip Dress
Weld Schedule
61
Move Away from

Dress
Reset Turn On Tip Dresser

DO[101]
No Tip Burn In
Required
R[20]
Yes
Do Tip Burn In Note: Tip burn in and wear
Weld Schedule compensation can be
R[20] skipped. This is to be used
only prior to tip change when
burn in and wear
Do Tip Wear Compensation compensation is not required
Gun 2 (Macro) after a tip dress.

DO[48]
[PR Home – Fine Move]

DO[28]
End
AS OF 2/4/2011 92 CUSW REL1.1

Tip Dress Ped Gun (Macro)
Start
Setup Gun 1 Burn in

Schedule R[19]
Set Robot in Tip Dress
DO[28]
Wait for Tip

Dress Dump Ext
DI[99]
Turn on Tip Dresser DO[101]
Wait for Tip

Dress Motor On
DI[101]
Do Tip Dress
Weld Schedule
60
Reset Turn on Tip Dresser

DO[101]
DO[100]
Wait for Tip Dress

Dump Retracted
DI[100]
Tip Burn In
No Required
R[19]
Yes
Do Tip Burn In
Weld Schedule
R[19]
Do Tip Wear Compensation

Gun 1 (Macro)

DO[28]
End
AS OF 2/4/2011 93 CUSW REL1.1

Tool Drop Preparation (Macro)
Start
Select Tool from Tool

Number R[16] A
Unknown
Set Application Error Output Set Application Error Output
Tool
User Alarm – Unexpected User Alarm – Tool Nest Not
Tool Present Empty
Reset App Error Output Reset App Error Output
Tool 1 Verify Part Not Present

(Macro)
Set Active MH Tool and Yes
Tool Nest 1
Gripper State for Drop Drop Tool Nest 1 (Macro)
Empty?
(Macro)
No

(Macro)
Tool Nest 2
Empty?
(Macro)
No

(Macro)
Tool Nest 3
Empty?
(Macro)
No

(Macro)
Tool Nest 4
Empty?
(Macro)
No
A
End
AS OF 2/4/2011 94 CUSW REL1.1

Tool Pick Preparation (Macro)
Start
Select Tool Nest from Pick

A
Tool GI[4] or Style Program
Unknown Set Application Error Output Set Application Error Output

Tool
User Alarm – Invalid Tool User Alarm – Tool Nest
Requested Empty
Reset App Error Output Reset App Error Output
Tool 1 Tool Nest 1 No

Empty?
Yes

Empty?
Yes

Empty?
Yes

Empty?
Yes
End
AS OF 2/4/2011 95 CUSW REL1.1

TEACH PENDANT LOGIC EXAMPLES
Contained in the following pages are examples of TP logic of the processes required for the WD program. The information contained in each section is
for REFERENCE ONLY.
AS OF 2/4/2011 96 CUSW REL1.1

Material Handling
1: !Material Handling Template ; 76: ;
2: !****************************** ; 77: !Jump To Program End ;
3: !Remove these comments ; 78: JMP LBL[1000] ;
4: !Before Build!!! ; 79: ;
5: !Rename Program as Necessary ; 80: LBL[20:Go To Work] ;
6: !Edit Program to Match Part Type ; 81: ;
7: ; 82: !Set Robot At Work ;
8: !Modify Zone Numbers and ; 83: DO[18:RbtAtWork]=ON ;
9: !Locations as Required ; 84: ;
10: ; 85: !Reset Robot At Pounce ;
11: !Uncomment the MACROs before ; 86: DO[25:RbtAtPounce]=OFF ;
12: ! finalizing the OLPs ; 87: ;
13: ; 88: !Wait For Go To Pickup 1 ;
14: !EXAMPLE PROGRAM ONLY ; 89: WAIT DI[49:GoToPickup1]=ON ;
15: !****************************** ; 90: ;
16: ; 91: !Reset Clear Of Pickup 1 ;
17: !Set Robot Payload ; 92: DO[49:ClrOfPickup1]=OFF ;
18: PAYLOAD[2] ; 93: ;
19: ; 94: !Reset Clear To Transfer ;
20: !Set Robot UTOOL Number ; 95: DO[31:CleartoTransfer]=OFF ;
21: UTOOL_NUM=1 ; 96: ;
22: ; 97: !MACRO-Zone Check ;
23: !Set Robot UFRAME Number ; 98: !(if necessary) ;
24: UFRAME_NUM=1 ; 99: CALL ENTRZON1 ;
25: ; 100: ;
26: !MACRO-Setup App Specific IO ; 101: !Move Over Pickup 1 ;
27: CALL APP_IO ; 102:L P[2] 1000mm/sec CNT100 ;
28: ; 103: ;
29: !Set Acknowledge Style ; 104: !MACRO-Verify Correct Tool ;
30: GO[1:ActiveStyleBits]=10 ; 105: !Call TOOL_VER ;
31: ; 106: ;
32: !Reset Coll Guard Sensitivity ; 107: !MACRO-Verify Part Not Present ;
33: COL GUARD ADJUST ; 108: Check No Part(1) ;
34: ; 109: ;
35: !****************************** ; 110: !MACRO-Open the Gripper ;
36: !TOOL CHANGE APPLICATION ONLY ; 111: Release Part(1) ;
37: ; 112: ;
38: !Set Desired Tool ID Register ; 113: !Set Coll Guard Sensitivity ;
39: R[2:Desired Tool ID]=2 ; 114: COL GUARD ADJUST R[42];
40: ; 115: ;
41: !MACRO-Check Tool ; 116: !Move To Pickup 1 ;
42: CALL CHK_TOOL ; 117:L P[3] 500mm/sec FINE ;
43: ; 118: ;
44: !MACRO-Set MH Tool ; 119: !MACRO-Check For Part Present ;
45: Set MH Tool(1) ; 120: Part Present(1) ;
46: !****************************** ; 121: ;
47: ; 122: !Set Reposition Tooling ;
48: !MACRO-Set Additional Gripper ; 123: !GO[2:ReposTooling]=1 ;
49: !States (if necessary) ; 124: ;
50: !Grip Part(2) ; 125: !Wait for Tooling Repositioned ;
51: ; 126: !WAIT GI[5:ToolingRepod1]=1 ;
52: !Move to Pounce ; 127: ;
53:J P[1] 100% CNT100 ; 128: !MACRO-Close The Gripper ;
54: ; 129: Grip Part(1) ;
55: !Set At Pounce Position Bit ; 130: ;
56: DO[25:RbtAtPounce]=ON ; 131: !Set At Pickup 1 ;
57: ; 132: DO[50:AtPickup1]=ON ;
58: !MACRO-Verify Part Not Present ; 133: ;
59: Check No Part(1) ; 134: !Select Payload With Parts ;
60: ; 135: PAYLOAD[3] ;
61: !MACRO-Open the Gripper ; 136: ;
62: Release Part(1) ; 137: !Wait for Tooling Repositioned ;
63: ; 138: !WAIT GI[5:ToolingRepod1]=1 ;
64: DO[89:PickOverride]=OFF ; 139: ;
65: DO[94:AbortPickReq]=OFF ; 140: !Reset Reposition Tooling ;
66: ; 141: !GO[2:ReposTooling]=0 ;
67: !Wait For Go To Work ; 142: ;
68: !or Return Home From Pounce ; 143: !Move Clear Fixt Part Presence ;
69: WAIT DI[31:GoToWork]=ON OR 144:L P[4] 1000mm/sec FINE ;
DI[25:RetFromPounce]=ON ; 145: ;
70: ; 146: !Wait For Exit Pickup 1 ;
71: !Check For Go To Work ; 147: WAIT DI[50:ExitPickup1]=ON ;
72: IF DI[31:GoToWork]=ON,JMP LBL[20] ; 148: ;
73: ; 149: !Reset Coll Guard Sensitivity ;
74: !Return Home From Pounce ; 150: COL GUARD ADJUST ;
75: CALL MVHMPNCE ; 151: ;
AS OF 2/4/2011 97 CUSW REL1.1
152: !MACRO-Check For Part Present ; 214: ;
153: Part Present(1) ; 215: !Set Robot UTOOL Number ;
154: ; 216: UTOOL_NUM=1 ;
155: !Reset At Pickup 1 ; 217: ;
156: DO[50:AtPickup1]=OFF ; 218: !Set Robot UFRAME Number ;
157: ; 219: !If Necessary ;
158: !Move Clear Of Pickup 1 ; 220: UFRAME_NUM=1 ;
159:L P[5] 1000mm/sec FINE ; 221: ;
160: ; 222: !Set Tooling Repositioned ;
161: !Set Clear Of Pickup 1 ; 223: !GO[2:ReposTooling]=2 ;
162: DO[49:ClrOfPickup1]=ON ; 224: ;
163: ; 225: !Move Clr Robot Part Present ;
164: !Set Clear To Transfer ; 226:L P[9] 1000mm/sec FINE ;
165: DO[31:CleartoTransfer]=ON ; 227: ;
166: ; 228: !MACRO-Verify No Part Present ;
167: !Set Clear Of Interference ; 229: Check No Part(1) ;
168: !Zone (If Necessary) ; 230: ;
169: DO[33:RbtClrZone1]=ON ; 231: !Wait For Exit Dropoff 1 ;
170: ; 232: !(if necessary) ;
171: !Move ; 233: WAIT DI[52:ExitDropoff1]=ON ;
172:L P[6] 1000mm/sec FINE ; 234: ;
173: ; 235: !Reset Coll Guard Sensitivity ;
174: !Insert Process Application ; 236: COL GUARD ADJUST ;
175: !as Required ; 237: ;
176: !CALL (MACRO) ; 238: !Reset At Dropoff 1 ;
177: ; 239: DO[52:AtDropoff1]=OFF ;
178: !Wait For Go To Dropoff 1 ; 240: ;
179: WAIT DI[51:GoToDropoff1]=ON ; 241: !Reset Tooling Repositioned ;
180: ; 242: !GO[2:ReposTooling]=0 ;
181: !MACRO-Zone Check ; 243: ;
182: !(If Necessary) ; 244: !Move Clear Of Dropoff 1 ;
183: CALL ENTRZON1 ; 245:J P[10] 100% CNT100 ;
184: ; 246: ;
185: !Reset Clear Of Dropoff 1 ; 247: !Set Clear Of Dropoff 1 ;
186: DO[51:ClrOfDropoff1]=OFF ; 248: DO[51:ClrOfDropoff1]=ON ;
187: ; 249: ;
188: !Reset Clear To Transfer ; 250: !Set Clear Of Interference Zone ;
189: DO[31:CleartoTransfer]=OFF ; 251: DO[33:RbtClrZone1]=ON ;
190: ; 252: ;
191: !Move Over Dropoff 1 ; 253: !Move Clear of Transfer ;
192:L P[7] 1000mm/sec CNT100 ; 254:J P[11] 100% FINE ;
193: ; 255: ;
194: !MACRO-Verify Correct Tool ; 256: !Set Clear To Transfer ;
195: !Call CHK_TOOL ; 257: DO[31:CleartoTransfer]=ON ;
196: ; 258: ;
197: !Set Coll Guard Sensitivity ; 259: !Reset Robot At Work ;
198: COL GUARD ADJUST R[42] ; 260: DO[18:RbtAtWork]=OFF ;
199: ; 261: ;
200: !Move To Dropoff 1 ; 262: !MACRO-Return To Home ;
201:L P[8] 1000mm/sec FINE ; 263: CALL MOV_HOME ;
202: ; 264: ;
203: !Set At Dropoff 1 ; 265: !Set Work Complete ;
204: DO[52:AtDropoff1]=ON ; 266: DO[19:WorkComplete]=ON ;
205: ; 267: ;
206: !Wait for Reposition Tooling ; 268: !Wait For Work Complete Ack ;
207: !WAIT GI[5:ToolingRepod1]=2 ; 269: WAIT DI[32:WorkCompleteAck]=ON ;
208: ; 270: ;
209: !MACRO-Open the Gripper ; 271: !Reset Work complete ;
210: Release Part(1) ; 272: DO[19:WorkComplete]=OFF ;
211: ; 273: ;
212: !Select Payload Without Parts ; 274: LBL[1000:End] ;
213: PAYLOAD[2] ; 275: ;
AS OF 2/4/2011 98 CUSW REL1.1

Dispense
1: !Carried Dispense Template ; 75: !Set Disp Robot in Process ;
2: !******************************** ; 76: DO[393:Disp1RbtinPrc]=ON ;
3: !Remove these comments ; 77: ;
4: !Before Build!!! ; 78: WAIT .10(sec) ;
5: !Rename Program as Necessary ; 79: ;
6: !Edit Program to Match Part Type ; 80: !Set Dispense Style ;
7: ; 81: GO[31:Disp1StyBits]=1 ;
8: !Modify Zone Numbers and ; 82: ;
9: !Locations as Required ; 83: WAIT .10(sec) ;
10: ; 84: ;
11: !Uncomment the MACROs before ; 85: !Set Disp Style Strobe ;
12: ! finalizing the OLPs ; 86: DO[394:Disp1StyStrobe]=ON ;
13: ; 87: ;
14: !EXAMPLE PROGRAM ONLY ; 88: !Wait for Disp in Process ;
15: !******************************** ; 89: WAIT DI[386:Dsp1DispenInPrc]=ON ;
16: ; 90: ;
17: !Set Robot Payload ; 91: !Reset Dispense Style ;
18: PAYLOAD[2] ; 92: GO[31:Disp1StyBits]=0 ;
19: ; 93: ;
20: !Set Robot UTOOL Number ; 94: !Reset Disp Style Strobe ;
21: UTOOL_NUM=1 ; 95: DO[394:Disp1StyStrobe]=OFF ;
22: ; 96: ;
23: !Set Robot UFRAME Number ; 97: !Set Coll Guard Sensitivity ;
24: UFRAME_NUM=1 ; 98: COL GUARD ADJUST R[42] ;
25: ; 99: ;
26: !MACRO-Setup App Specific IO ; 100: !Move Seal Start, Turn On Gun ;
27: CALL APP_IO ; 101:L P[2] 1000mm/sec CNT100 SS[1] ;
28: ; 102: ;
29: !Set Acknowledge Style ; 103: !Move along Path ;
30: GO[1:ActiveStyleBits]=10 ; 104:L P[3] 1000mm/sec CNT100 ;
31: ; 105: ;
32: !Reset Coll Guard Sensitivity ; 106: !Move To Seal End, Turn Off Gun ;
33: COL GUARD ADJUST ; 107:L P[4] 1000mm/sec CNT100 SE ;
34: ; 108: ;
35: !Reset Clear To Transfer ; 109: !Move Clear of Part ;
36: DO[31:CleartoTransfer]=OFF ; 110:L P[5] 1000mm/sec FINE ;
37: ; 111: ;
38: !Move to Pounce ; 112: !Reset Coll Guard Sensitivity ;
39:J P[1] 100% FINE ; 113: COL GUARD ADJUST ;
40: ; 114: ;
41: !Set At Pounce Position Bit ; 115: !Set Dispense Complete ;
42: DO[25:RbtAtPounce]=ON ; 116: DO[401:Disp1Complete]=ON ;
43: ; 117: ;
44: !Wait For Go To Work ; 118: !Wait for Dispense Vol. OK ;
45: !or Return Home From Pounce ; 119: WAIT DI[387:Dsp1VolumeOK]=ON ;
46: WAIT DI[31:GoToWork]=ON OR 120: ;
DI[25:RetFromPounce]=ON ; 121: !Reset Dispense Complete ;
47: ; 122: DO[401:Disp1Complete]=OFF ;
48: !Check For Go To Work ; 123: ;
49: IF DI[31:GoToWork]=ON,JMP LBL[20] ; 124: !Reset Disp Robot in Process ;
50: ; 125: DO[393:Disp1RbtinPrc]=OFF ;
51: !Return Home From Pounce ; 126: ;
52: CALL MVHMPNCE ; 127: !Post-process Dispense Equip ;
53: ; 128: !(insert statements) ;
54: !Jump To Program End ; 129: ;
55: JMP LBL[1000] ; 130: !MACRO-Return To Home ;
56: ; 131: CALL MOV_HOME ;
57: LBL[20:Go To Work] ; 132: ;
58: ; 133: !Set Work Complete ;
59: !Set Robot At Work ; 134: DO[19:WorkComplete]=ON ;
60: DO[18:RbtAtWork]=ON ; 135: ;
61: ; 136: !Set Clear To Transfer ;
62: !Reset Robot At Pounce ; 137: DO[31:CleartoTransfer]=ON ;
63: DO[25:RbtAtPounce]=OFF ; 138: ;
64: ; 139: !Set Clear Of Interference Zone ;
65: !MACRO-Zone Check ; 140: DO[33:RbtClrZone1]=ON ;
66: !(if necessary) ; 141: ;
67: !CALL ENTRZON1 ; 142: !Wait For Work Complete Ack ;
68: ; 143: WAIT DI[32:WorkCompleteAck]=ON ;
69: !Pre-process Dispense Equipment ; 144: ;
70: !(insert statements) ; 145: !Reset Work complete ;
71: ; 146: DO[19:WorkComplete]=OFF ;
72: !Wait for Dispenser Ready ; 147: ;
73: WAIT (DI[385:Dsp1DispenRdy]=ON) ; 148: LBL[1000:End] ;
74: ; 149: ;
AS OF 2/4/2011 99 CUSW REL1.1

Spot Welding
1: !Carried Spot Welding Template ; 70: !Select Schedule Weld 1 ;
2: !******************************** ; 71:L P[3] 100mm/sec FINE
3: !Remove these comments ; : SPOT[SD=1,P=1,S=1,ED=1] ;
4: !Before Build!!! ; 72: ;
5: !Rename Program as Necessary ; 73: !Move to Weld 2 ;
6: !Edit Program to Match Part Type ; 74: !insert motion if necessary ;
7: ; 75:L P[4] 1000mm/sec FINE ;
9: !Locations as Required ; 77: !Select Schedule Weld 2 ;
10: ; 78:L P[5] 100mm/sec FINE
11: !Uncomment the MACROs before ; : SPOT[SD=1,P=1,S=1,ED=1] ;
13: ; 80: !Move Clear of Clamps ;
14: !EXAMPLE PROGRAM ONLY ; 81:L P[6] 1000mm/sec FINE ;
15: !******************************** ; 82: ;
16: ; 83: !Set Clear to Unclamp Early ;
17: !Set Robot Payload ; 84: DO[65:Clr2UnclampEarly]=ON ;
18: PAYLOAD[2] ; 85: ;
19: ; 86: !Check for Tip Dress Req ;
20: !Set Robot UTOOL Number ; 87: IF DI[28:TipDressGunReq]=ON,JMP LBL[30] ;
21: UTOOL_NUM=1 ; 88: ;
22: ; 89: !MACRO-Return To Home ;
23: !Set Robot UFRAME Number ; 90: CALL MOV_HOME ;
24: UFRAME_NUM=1 ; 91: ;
26: !MACRO-Setup App Specific IO ; 93: DO[19:WorkComplete]=ON ;
27: CALL APP_IO ; 94: ;
29: !Set Acknowledge Style ; 96: DO[31:CleartoTransfer]=ON ;
30: GO[1:ActiveStyleBits]=1 ; 97: ;
32: !Reset Clear To Transfer ; 99: DO[33:RbtClrZone1]=ON ;
33: DO[31:CleartoTransfer]=OFF ; 100: ;
34: ; 101: !Wait For Work Complete Ack ;
35: !Move to Pounce ; 102: WAIT DI[32:WorkCompleteAck]=ON ;
36:J P[1] 100% FINE ; 103: ;
37: ; 104: !Reset Work complete ;
38: !Set At Pounce Position Bit ; 105: DO[19:WorkComplete]=OFF ;
39: DO[25:RbtAtPounce]=ON ; 106: ;
40: ; 107: JMP LBL[1000] ;
42: !or Return Home From Pounce ; 109: LBL[30] ;
43: WAIT DI[31:GoToWork]=ON OR 110: ;
DI[25:RetFromPounce]=ON ; 111: !Move Clear of Transfer ;
44: ; 112: !To Tip Dress ;
45: !Check For Go To Work ; 113:J P[7] 50% FINE ;
48: !Return Home From Pounce ; 116: DO[19:WorkComplete]=ON ;
51: !Jump To Program End ; 119: DO[31:CleartoTransfer]=ON ;
52: JMP LBL[1000] ; 120: ;
54: LBL[20:Go To Work] ; 122: DO[33:RbtClrZone1]=ON ;
55: ; 123: ;
56: !Set Robot At Work ; 124: !Wait For Work Complete Ack ;
57: DO[18:RbtAtWork]=ON ; 125: WAIT DI[32:WorkCompleteAck]=ON ;
58: ; 126: ;
59: !Reset Robot At Pounce ; 127: !Reset Work complete ;
60: DO[25:RbtAtPounce]=OFF ; 128: DO[19:WorkComplete]=OFF ;
61: ; 129: ;
62: !MACRO-Zone Check ; 130: !MACRO-Tip Dress Gun 1 ;
63: !(if necessary) ; 131: CALL TPDRSGN1(62) ;
64: CALL ENTRZON1 ; 132: ;
66: !Move to Weld 1 ; 134: CALL MOV_HOME ;
67: !insert motion if necessary ; 135: ;
68:L P[2] 1000mm/sec FINE ; 136: LBL[1000:End] ;
69: ; 137: ;
AS OF 2/4/2011 100 CUSW REL1.1

Stud Welding
1: !Carried Stud Welding Template ; 53: ;
2: !******************************** ; 54: LBL[20:Go To Work] ;
4: !Before Build!!! ; 56: !Set Robot At Work ;
5: !Rename Program as Necessary ; 57: DO[18:RbtAtWork]=ON ;
6: !Edit Program to Match Part Type ; 58: ;
7: ; 59: !Reset Robot At Pounce ;
8: !Modify Zone Numbers and ; 60: DO[25:RbtAtPounce]=OFF ;
9: !Locations as Required ; 61: ;
10: ; 62: !MACRO-Zone Check ;
11: !Uncomment the MACROs before ; 63: !(if necessary) ;
12: ! finalizing the OLPs ; 64: CALL ENTRZON1 ;
13: ; 65: ;
14: !EXAMPLE PROGRAM ONLY ; 66: !Move to Weld 1 ;
15: !******************************** ; 67: !insert motion if necessary ;
16: ; 68:L P[2] 1000mm/sec FINE ;
17: !Set Robot Payload ; 69: ;
18: PAYLOAD[2] ; 70: !Select Schedule Weld 1 ;
19: ; 71:L P[3] 100mm/sec FINE
20: !Set Robot UTOOL Number ; : SPOT[S=1] ;
21: UTOOL_NUM=1 ; 72: ;
22: ; 73: !Move to Weld 2 ;
23: !Set Robot UFRAME Number ; 74: !insert motion if necessary ;
24: UFRAME_NUM=1 ; 75:L P[4] 1000mm/sec FINE ;
25: ; 76: ;
26: !MACRO-Setup App Specific IO ; 77: !Select Schedule Weld 2 ;
27: CALL APP_IO ; 78:L P[5] 100mm/sec FINE
28: ; : SPOT[S=1] ;
29: !Set Acknowledge Style ; 79: ;
30: GO[1:ActiveStyleBits]=1 ; 80: !Move Clear of Clamps ;
31: ; 81:L P[6] 1000mm/sec FINE ;
32: !Reset Clear To Transfer ; 82: ;
33: DO[31:CleartoTransfer]=OFF ; 83: !Set Clear to Unclamp Early ;
34: ; 84: DO[65:Clr2UnclampEarly]=ON ;
35: !Move to Pounce ; 85: ;
36:J P[1] 100% FINE ; 86: !MACRO-Return To Home ;
38: !Set At Pounce Position Bit ; 88: ;
39: DO[25:RbtAtPounce]=ON ; 89: !Set Work Complete ;
40: ; 90: DO[19:WorkComplete]=ON ;
42: !or Return Home From Pounce ; 92: !Set Clear To Transfer ;
43: WAIT DI[31:GoToWork]=ON OR 93: DO[31:CleartoTransfer]=ON ;
DI[25:RetFromPounce]=ON ; 94: ;
45: !Check For Go To Work ; 96: DO[33:RbtClrZone1]=ON ;
47: ; 98: !Wait For Work Complete Ack ;
48: !Return Home From Pounce ; 99: WAIT DI[32:WorkCompleteAck]=ON ;
50: ; 101: !Reset Work complete ;
51: !Jump To Program End ; 102: DO[19:WorkComplete]=OFF ;
52: JMP LBL[1000] ; 103: ;
AS OF 2/4/2011 101 CUSW REL1.1

Tip Change (Style #3)
1: !Tip Change Template ; 44: !Pulse W1 Water Off ;
2: !****************************** ; 45: DO[587:W1WtrOff]=PULSE,1.0sec ;
4: !Before Build!!! ; 46: !Wait for WaterOK and ValveClosed;
5: !Rename Program as Necessary ; 46: WAIT (DI[785:W1OKtoWeld]=OFF) AND ;
6: !Edit Program to Match Part Type ; 46: (DI[786:W1ValveClosed]=ON) ;
7: ; 46: ;
8: !Modify Zone Numbers and ; 47: !Set Robot at Service ;
9: !Locations as Required ; 48: DO[26:RbtAtService]=ON ;
10: ; 49: ;
11: !Uncomment the MACROs before ; 50: !Set Ready for Tip Change ;
12: ! finalizing the OLPs ; 51: DO[30:RdyForTipChg]=ON ;
13: ; 52: ;
14: !EXAMPLE PROGRAM ONLY ; 53: !Wait for Service Complete ;
15: !****************************** ; 54: WAIT (DI[26:ServiceCompltReq]=ON) ;
16: ; 55: ;
17: !Set Robot Payload ; 56: !Reset Robot at Service ;
18: PAYLOAD[2] ; 57: DO[26:RbtAtService]=OFF ;
19: ; 58: ;
20: !Set Robot UTOOL Number ; 59: !Reset Ready for Tip Change ;
21: UTOOL_NUM=1 ; 60: DO[30:RdyForTipChg]=OFF ;
22: ; 61: ;
23: !Set Robot UFRAME Number ; 62: !MACRO-Reset Stepper ;
24: UFRAME_NUM=1 ; 63: CALL RST_STPR ;
25: ; 64: ;
26: !MACRO-Setup App Specific IO ; 65: !MACRO-Seat Caps Gun 1 ;
27: CALL APP_IO ; 66: CALL TW_PRSRT(1,500,2,4,1,10,5,15) ;
28: ; 67: ;
29: !Set Acknowledge Style ; 68: !Tip Wear Compensation Gun 1 ;
30: GO[1:ActiveStyleBits]=3 ; 69: CALL WR_UPDAT(1,0) ;
31: ; 70: ;
32: !Insert Dress Approach Movement ; 71: !Insert Dress Approach Movement ;
33: !(if necessary) ; 72: !(if necessary) ;
34: ; 73: ;
35: !MACRO-Tip Dress Gun 1 ; 74: !Pulse W1 Reset Water Saver ;
36: CALL TPDRSGN1(0) ; 75: DO[586:W1RstWtrSvr]=PULSE,1.0sec ;
37: ; 76: ;
37: !Wait for TipDressComplete ; 76: !Wait for WaterOK ;
37: WAIT (1) sec. ; 76: WAIT (DI[785:W1OKtoWeld]=ON) ;
37: ; 76: ;
38: !Reset Tip Dress Complete ; 77: !MACRO-Tip Dress Gun 1 ;
39: DO[29:TipDressComplt]=OFF ; 78: CALL TPDRSGN1(58) ;
40: ; 79: ;
41: !Move to Tip Change Position ; 80: !MACRO-Return To Home ;
42:J P[1] 100% FINE ; 81: CALL MOV_HOME ;
43: ; 82: ;
Purge (Style #4)

1: !Purge Template ; 24: DO[97:ExtPurg1InProgrs]=ON ;
2: !****************************** ; 25: ;
3: !Remove these comments ; 26: !Pre-process Dispense Equipment ;
4: !Before Build!!! ; 27: !(insert statements) ;
6: !Edit Program to Match Part Type ; 29: !Turn On Gun-Purge Schedule ;
7: ; 30: DO[416:Disp1Purge]=ON ;
9: !Locations as Required ; 32: !Wait 'X' Seconds ;
10: ; 33: WAIT 7.00(sec) ;
11: !Uncomment the MACROs before ; 34: ;
12: ! finalizing the OLPs ; 35: !Turn Off Gun ;
13: ; 36: DO[416:Disp1Purge]=OFF ;
14: !EXAMPLE PROGRAM ONLY ; 37: ;
15: !****************************** ; 38: !Post-process Disp Equipment ;
16: ; 39: !(insert statements) ;
17: !MACRO-Setup App Specific IO ; 40: ;
18: CALL APP_IO ; 41: !Reset Ext Purge 1 in Progress ;
19: ; 42: DO[97:ExtPurg1InProgrs]=OFF ;
20: !Set Acknowledge Style ; 43: ;
21: GO[1:ActiveStyleBits]=3 ; 44: !MACRO-Home IO (if necessary) ;
22: ; 45: CALL HOME_IO ;
23: !Set Ext Purge 1 in Progress ; 46: ;
AS OF 2/4/2011 102 CUSW REL1.1

Tip Burn In (Style #5)
1: !Tip Burn In Template ; 21: UTOOL_NUM=1 ;
2: !****************************** ; 22: ;
3: !Remove these comments ; 23: !Set Robot UFRAME Number ;
4: !Before Build!!! ; 24: UFRAME_NUM=1 ;
6: !Edit Program to Match Part Type ; 29: !Set Acknowledge Style ;
7: ; 30: GO[1:ActiveStyleBits]=5 ;
9: !Locations as Required ; 32: !Move to Service Position ;
10: ; 33: !if necessary ;
11: !Uncomment the MACROs before ; 34:J PR[5] 100% FINE ;
13: ; 36: !MACRO-Tip Burn In ;
14: !EXAMPLE PROGRAM ONLY ; 37: CALL TPBURNIN ;
15: !****************************** ; 38: ;
17: !Set Robot Payload ; 40: CALL MOV_HOME ;
18: PAYLOAD[2] ; 41: ;
19: ; 42: !MACRO-Home IO ;
20: !Set Robot UTOOL Number ; 43: CALL MOVE_IO ;
Service Program (Style #6)

1: !Service Program Template ; 24: UFRAME_NUM=1 ;
2: !****************************** ; 25: ;
3: !Remove these comments ; 26: !MACRO-Setup App Specific IO ;
4: !Before Build!!! ; 27: CALL APP_IO ;
6: !Edit Program to Match Part Type ; 29: !Set Acknowledge Style ;
9: !Locations as Required ; 32: !Move to Service Position ;
10: ; 33:J PR[5] 100% FINE ;
12: ! finalizing the OLPs ; 35: !Set Robot at Service ;
13: ; 36: DO[26:RbtAtService]=ON ;
15: !****************************** ; 38: !Wait for Service Complt Req ;
16: ; 39: WAIT (DI[26:ServiceCompltReq]=ON) ;
18: PAYLOAD[2] ; 41: !Reset Robot at Service ;
19: ; 42: DO[26:RbtAtService]=OFF ;
20: !Set Robot UTOOL Number ; 43: ;
21: UTOOL_NUM=1 ; 44: !MACRO-Return To Home ;
23: !Set Robot UFRAME Number ; 46: ;

1: !Tip Dress 1st Gun Template ; 21: UTOOL_NUM=1 ;
2: !****************************** ; 22: ;
6: !Edit Program to Match Part Type ; 26: !MACRO-Setup App Specific IO ;
7: ; 27: CALL APP_IO ;
9: !Locations as Required ; 29: !Set Acknowledge Style ;
12: ! finalizing the OLPs ; 32: !Insert Approach Movement ;
13: ; 33: !(if necessary) ;
15: !****************************** ; 35: !MACRO-Tip Dress Gun 1 ;
16: ; 36: CALL TPDRSGN1(60) ;
18: PAYLOAD[2] ; 38: !MACRO-Return To Home ;
AS OF 2/4/2011 103 CUSW REL1.1

1: !Tip Dress 2nd Gun Template ; 21: UTOOL_NUM=1 ;
2: !****************************** ; 22: ;
12: ! finalizing the OLPs ; 32: !Insert Approach Movement ;
13: ; 33: !(if necessary) ;
15: !****************************** ; 35: !MACRO-Tip Dress Gun 2 ;
16: ; 36: CALL TPDRSGN2(61) ;
Tool Change (Style #9)

1: !Tool Change Template ; 21: UTOOL_NUM=1 ;
2: !****************************** ; 22: ;
12: ! finalizing the OLPs ; 32: !Set Desired Tool ID ;
13: ; 33: R[2]=GI[4:PickToolBits] ;
15: !****************************** ; 35: !MACRO-Check Tool on Wrist ;
16: ; 36: CALL CHK_TOOL ;
AS OF 2/4/2011 104 CUSW REL1.1

Check ATI Errors (Macro)
1: !****************************** ; 76: ;
2: !MACRO CHECK ATI ERRORS ; 77: !OK - Exit ;
3: !****************************** ; 78: JMP LBL[999] ;
4: !Parameters: AR[] ; 79: ;
5: !1: Current Sequence ; 80: !****************************** ;
6: !****************************** ; 81: !READY TO UNLATCH ;
7: ; 82: !****************************** ;
8: !Jump to Current Sequence ; 83: LBL[6:ReadyToUnlatch] ;
9: R[16]=AR[1] ; 84: ;
10: JMP LBL[R[16]] ; 85: !Set ATI Recovery Method ;
11: ; 86: R[17]=0 ;
12: !****************************** ; 87: ;
13: !READY TO PICK/LATCH/UNLATCH ; 88: IF (!DI[640:ToolStndIntlkV1]),JMP LBL[640] ;
14: !****************************** ; 89: IF (!DI[641:ToolStndIntlkV2]),JMP LBL[641] ;
15: LBL[1:ReadyToPick] ; 90: ;
16: LBL[3:Latch] ; 91: !OK - Exit ;
17: LBL[7:Unlatch] ; 92: JMP LBL[999] ;
18: ; 93: ;
19: !Set ATI Recovery Method ; 94: !****************************** ;
20: R[17]=1 ; 95: !ERROR HANDLING ;
21: ; 96: !****************************** ;
22: IF (DI[648:RTLMismatch]),JMP LBL[648] ; 97: ;
23: IF (DI[649:TSIVMismatch]),JMP LBL[649] ; 98: !AUX POWER ;
24: IF (DI[650:LatchOverLoad]),JMP LBL[650] ; 99: LBL[635] ;
25: IF (DI[651:UnlatchOverLoad]),JMP LBL[651] ; 100: UALM[7] ;
26: IF (DI[652:SpareOverload]),JMP LBL[652] ; 101: JMP LBL[900] ;
27: IF (DI[659:TSIVFault]),JMP LBL[659] ; 102: ;
28: IF (DI[660:RTLFault]),JMP LBL[660] ; 103: !READY TO LOCK1 ;
29: IF (DI[653:RTLrtlvMismatch]),JMP LBL[653] ; 104: LBL[636] ;
30: IF (DI[654:TSIVtsrvMismatch]),JMP LBL[654] ; 105: UALM[8] ;
31: IF (DI[655:UnsafeUnlatch]),JMP LBL[655] ; 106: JMP LBL[900] ;
32: IF (DI[656:LckUnlckSensFlt]),JMP LBL[656] ; 107: ;
33: IF (DI[657:LatchNotComplt]),JMP LBL[657] ; 108: !READY TO LOCK2 ;
34: IF (DI[658:UnlatchNotComplt]),JMP LBL[658] ; 109: LBL[637] ;
35: ; 110: UALM[9] ;
36: !OK - Exit ; 111: JMP LBL[900] ;
37: JMP LBL[999] ; 112: ;
38: ; 113: !TOOL STAND INTERLOCK1 ;
39: !****************************** ; 114: LBL[640] ;
40: !READY TO LATCH ; 115: UALM[10] ;
41: !****************************** ; 116: JMP LBL[900] ;
42: LBL[2:ReadyToLatch] ; 117: ;
43: ; 118: !TOOL STAND INTERLOCK2 ;
44: !Set ATI Recovery Method ; 119: LBL[641] ;
45: R[17]=0 ; 120: UALM[11] ;
46: ; 121: JMP LBL[900] ;
47: IF (!DI[636:ReadyToLock1]),JMP LBL[636] ; 122: ;
48: IF (!DI[637:ReadyToLock2]),JMP LBL[637] ; 123: !RTL MISMATCH ;
49: ; 124: LBL[648] ;
50: !OK - Exit ; 125: UALM[12] ;
51: JMP LBL[999] ; 126: JMP LBL[900] ;
52: ; 127: ;
53: !****************************** ; 128: !TSIV MISMATCH ;
54: !EXIT PICK/RDY TO DROP/EXT DROP ; 129: LBL[649] ;
55: !****************************** ; 130: UALM[13] ;
56: LBL[4:ExitPick] ; 131: JMP LBL[900] ;
57: LBL[5:ReadyToDrop] ; 132: ;
58: LBL[8:ExitDrop] ; 133: !LATCH OVERLOAD ;
59: ; 134: LBL[650] ;
60: !Set ATI Recovery Method ; 135: UALM[14] ;
61: R[17]=0 ; 136: JMP LBL[900] ;
62: ; 137: ;
63: IF (DI[648:RTLMismatch]),JMP LBL[648] ; 138: !UNLATCH OVERLOAD ;
64: IF (DI[649:TSIVMismatch]),JMP LBL[649] ; 139: LBL[651] ;
65: IF (DI[650:LatchOverLoad]),JMP LBL[650] ; 140: UALM[15] ;
66: IF (DI[651:UnlatchOverLoad]),JMP LBL[651] ; 141: JMP LBL[900] ;
67: IF (DI[652:SpareOverload]),JMP LBL[652] ; 142: ;
68: IF (DI[659:TSIVFault]),JMP LBL[659] ; 143: !SPARE OVERLOAD ;
69: IF (DI[660:RTLFault]),JMP LBL[660] ; 144: LBL[652] ;
70: IF (DI[653:RTLrtlvMismatch]),JMP LBL[653] ; 145: UALM[16] ;
71: IF (DI[654:TSIVtsrvMismatch]),JMP LBL[654] ; 146: JMP LBL[900] ;
72: IF (DI[655:UnsafeUnlatch]),JMP LBL[655] ; 147: ;
73: IF (DI[656:LckUnlckSensFlt]),JMP LBL[656] ; 148: !RTLRTLV MISMATCH ;
74: IF (DI[657:LatchNotComplt]),JMP LBL[657] ; 149: LBL[653] ;
75: IF (DI[658:UnlatchNotComplt]),JMP LBL[658] ; 150: UALM[17] ;
AS OF 2/4/2011 105 CUSW REL1.1
151: JMP LBL[900] ; 189: !RECOVERY ;
152: ; 190: !****************************** ;
153: !TSIVTSRV MISMATCH ; 191: ;
154: LBL[654] ; 192: LBL[900:Recovery] ;
155: UALM[18] ; 193: ;
156: JMP LBL[900] ; 194: !Check Recovery Type ;
157: ; 195: IF R[17]=1,JMP LBL[910] ;
158: !UNSAFE UNLATCH ; 196: ;
159: LBL[655] ; 197: !Set Clear Errors ;
160: UALM[19] ; 198: DO[635:ClearErrs]=ON ;
161: JMP LBL[900] ; 199: ;
162: ; 200: !Wait 2 Seconds ;
163: !LOCK UNLOCK SENSOR FAULT ; 201: WAIT 2.00(sec) ;
164: LBL[656] ; 202: ;
165: UALM[20] ; 203: !Reset Clear Errors ;
166: JMP LBL[900] ; 204: DO[635:ClearErrs]=OFF ;
167: ; 205: ;
168: !LATCH NOT COMPLETE ; 206: !Retry ;
169: LBL[657] ; 207: JMP LBL[R[16]] ;
170: UALM[21] ; 208: ;
171: JMP LBL[900] ; 209: LBL[910] ;
172: ; 210: ;
173: !UNLATCH NOT COMPLETE ; 211: !Reset Latch and Unlatch Tool ;
174: LBL[658] ; 212: DO[632:LatchOrLock]=OFF ;
175: UALM[22] ; 213: DO[633:UnlatchOrUnlock]=OFF ;
176: JMP LBL[900] ; 214: ;
177: ; 215: !Set Clear Errors ;
178: !TSIV FAULT ; 216: DO[635:ClearErrs]=ON ;
179: LBL[659] ; 217: ;
180: UALM[23] ; 218: !Wait 2 Seconds ;
181: JMP LBL[900] ; 219: WAIT 2.00(sec) ;
182: ; 220: ;
183: !RTL FAULT ; 221: !Reset Clear Errors ;
184: LBL[660] ; 222: DO[635:ClearErrs]=OFF ;
185: UALM[24] ; 223: ;
186: JMP LBL[900] ; 224: LBL[999:End] ;
187: ; 225: ;
188: !****************************** ;
Check Tool (Macro)

1: !****************************** ; 17: IF (!DI[644:ToolPresent] AND R[1]=15),JMP
2: !MACRO CHECK TOOL ON WRIST ; LBL[2] ;
3: !****************************** ; 18: ;
4: ; 19: !Drop Prep and Drop Tool ;
5: LBL[1:Verify Tool] ; 21: CALL PREPDROP ;
6: ; 22: ;
7: !Set Current Tool ID and ; 23: JMP LBL[1] ;
8: !Line Number ; 24: ;
9: R[1]=(GI[41:ToolIDswtch1Bits]) ; 25: LBL[2:Pick Tool] ;
10: R[8]=(GI[45:ToolIDSwtch5Bits]) ; 26: ;
11: GO[3:ToolIDOnWrstBits]=R[1] ; 27: !Select Pick Fixture & Pick ;
12: ; 28: CALL PREPPICK ;
13: !Is Tool ID Correct? ; 29: ;
14: IF R[1]=R[2],JMP LBL[999] ; 30: JMP LBL[1] ;
15: ; 31: ;
16: !Is Tool on Wrist? ; 32: LBL[999:End] ;
33: ;
AS OF 2/4/2011 106 CUSW REL1.1

Drop Tool Nest 1 (Macro)
1: !****************************** ; 67: !Wait for ATI ;
2: !MACRO DROP TOOL IN NEST 1 ; 68: WAIT ((DI[633:ToolUnLocked] AND
3: !****************************** ; !DI[632:ToolLocked]) OR
4: ; : DO[645:GeneralFaults]) ;
5: UTOOL_NUM=5 ; 69: ;
6: UFRAME_NUM=0 ; 70: !Check for Errors ;
7: ; 71: IF DO[645:GeneralFaults]=OFF,JMP LBL[17] ;
8: DO[635:ClearErrs]=PULSE,1.0sec ; 72: ;
9: ; 73: !MACRO-ATI State Check - Seq7 ;
10: !Set Request to Enter Tool Nest ; 74: CALL ATI_CHCK(7) ;
11: DO[71:Req2EntrToolNest]=ON ; 75: ;
12: ; 76: JMP LBL[7] ;
13: !Wait Clear to Enter Tool Nest ; 77: ;
14: WAIT DI[81:Clr2EntToolNest]=ON ; 78: LBL[17:ATIUnlocked] ;
15: ; 79: ;
16: !Reset Clear of Tool Nest ; 80: !Set Payload Without Tool ;
17: DO[72:ClearOfToolNest]=OFF ; 81: PAYLOAD[2] ;
18: ; 82: ;
19: !Reset Request to Enter Nest ; 83: UTOOL_NUM=9 ;
20: DO[71:Req2EntrToolNest]=OFF ; 84: UFRAME_NUM=0 ;
21: ; 85: ;
22: !MACRO-Set Tool Device Offline ; 86:L PR[106:ToolNest1Pick] 150mm/sec FINE ;
23: CALL DV_OFFLN(2,31,10) ; 87: ;
23: CALL DV_OFFLN(2,39,10) ; 87: !Move Clear of Tool in Nest IO ;
24: ; 88: !PR[114:ToolOffset4] ;
25: !Move to Tool Nest Perch/Approach ; 89: !X=0 Y=0 Z=-15 Rx=0 Ry=0 Rz=0 ;
26:J P[3:Perch In] 100% FINE ; 90:L PR[106:ToolNest1Pick] 150mm/sec FINE
27: ; Tool_Offset,PR[114:ToolOffset4]
28: !PR[111:ToolOffset1] ; : ;
29: !X=-150 Y=0 Z=65 Rx=0 Ry=0 Rz=0 ; 91: ;
30:L PR[101:ToolNest1Drop] 1200mm/sec FINE 92: !Wait for Tool in Nest 1 ;
Tool_Offset,PR[111:ToolOffset1] 93: !Check for Disengagement ;
: ; 94: !of Tool Changer ;
31: ; 95: WAIT DI[73:ToolInNest1]=ON ;
32: !PR[112:ToolOffset2] ; 96: ;
33: !X=-5 Y=0 Z=65 Rx=0 Ry=0 Rz=0 ; 97: !MACRO-ATI State Check - Seq8 ;
34:L PR[101:ToolNest1Drop] 200mm/sec FINE 98: IF DO[645:GeneralFaults]=OFF,JMP LBL[8] ;
Tool_Offset,PR[112:ToolOffset2] 99: ;
: ; 100: !MACRO-ATI State Check ;
35: ; 101: CALL ATI_CHCK(8) ;
36: !PR[113:ToolOffset3] ; 102: ;
37: !X=0 Y=0 Z=25 Rx=0 Ry=0 Rz=0 ; 103: !Wait for Tool in Nest 1 ;
38:L PR[101:ToolNest1Drop] 50mm/sec FINE 104: !Check for Disengagement ;
Tool_Offset,PR[113:ToolOffset3] 105: !of Tool Changer ;
: ; 106: WAIT DI[73:ToolInNest1]=ON ;
39: ; 107: ;
40: !MACRO-ATI State Check - Seq5 ; 108: LBL[8] ;
41: IF DO[645:GeneralFaults]=ON,CALL ATI_CHCK(5) ; 109: !Clear of Tool in Nest ;
42: ; 110: ;
43: !Reset Out of Nest ; 111: !PR[115:ToolOffset5] ;
44: DO[637:OutOfNest]=OFF ; 112: !X=0 Y=0 Z=-155 Rx=0 Ry=0 Rz=0 ;
45: ; 113:L PR[106:ToolNest1Pick] 150mm/sec FINE
46: !Move to Tool Nest ; Tool_Offset,PR[115:ToolOffset5]
47: UTOOL_NUM=5 ; : ;
48:L PR[101:ToolNest1Drop] 50mm/sec FINE ; 114: ;
49: ; 115: !Reset Unlatch Tool ;
50: !Wait for Tool in Nest 1 ; 116: DO[633:UnlatchOrUnlock]=OFF ;
51: WAIT DI[73:ToolInNest1]=ON ; 117: ;
52: ; 118: !Set Out of Nest ;
53: !MACRO-ATI State Check - Seq6 ; 119: DO[637:OutOfNest]=ON ;
54: CALL ATI_CHCK(6) ; 120: ;
55: ; 121: !Clear Ati Errors ;
56: LBL[7:RetryATISeq7] ; 122: DO[635:ClearErrs]=PULSE,1.0sec ;
57: ; 123: ;
58: !Reset Latch Tool ; 124: UTOOL_NUM=9 ;
59: DO[632:LatchOrLock]=OFF ; 125: UFRAME_NUM=0 ;
60: ; 126: ;
61: !Set Unlatch Tool ; 127: !Move Clear of Tool Nest ;
62: DO[633:UnlatchOrUnlock]=ON ; 128:J P[2:Perch Out] 50% FINE ;
63: ;
64: !Wait for ATI switches to settle in ;
64: WAIT DI[633:ToolUnLocked]=ON TIMEOUT,LBL[633] ;
65: LBL[633] ;
66: ;
AS OF 2/4/2011 107 CUSW REL1.1

1: !****************************** ; 71: !X=0 Y=0 Z=-25 Rx=0 Ry=0 Rz=0 ;
2: !MACRO PICK TOOL FROM NEST 1 ; 72:L PR[106:ToolNest1Pick] 150mm/sec FINE
3: !****************************** ; Tool_Offset,PR[117:ToolOffset7]
4: ; : ;
5: UTOOL_NUM=9 ; 73:L PR[106:ToolNest1Pick] 50mm/sec FINE ;
6: UFRAME_NUM=0 ; 74: ;
7: ; 75: !ATI State Check - Seq2 ;
8: !Move to Tool Nest Perch ; 76: CALL ATI_CHCK(2) ;
9:J P[1:Perch In] 100% FINE ; 77: ;
10: ; 78: LBL[3:RetryATISeq3] ;
11: !Clear Ati Errors ; 79: ;
12: DO[635:ClearErrs]=PULSE,1.0sec ; 80: !Reset Unlatch Tool ;
13: ; 81: DO[633:UnlatchOrUnlock]=OFF ;
14: !Set Request to Enter Tool Nest ; 82: ;
15: DO[71:Req2EntrToolNest]=ON ; 83: !Set Latch Tool ;
16: ; 84: DO[632:LatchOrLock]=ON ;
17: !Wait Clear to Enter Tool Nest ; 85: ;
18: WAIT DI[81:Clr2EntToolNest]=ON ; 86: !MACRO-Set Tool Devices Online ;
19: ; 87: CALL DV_ONLN(2,31,0) ;
20: !Reset Clear of Tool Nest ; 87: CALL DV_ONLN(2,39,0) ;
21: DO[72:ClearOfToolNest]=OFF ; 88: ;
22: ; 89: WAIT DI[632:ToolLocked]=ON TIMEOUT,LBL[632] ;
23: !Reset Request to Enter Nest ; 90: LBL[632] ;
24: DO[71:Req2EntrToolNest]=OFF ; 91: ;
25: ; 92: !Wait for ATI ;
26: ! 93: WAIT ((DI[632:ToolLocked] AND
27: ; !DI[633:ToolUnLocked]) OR
28: !Move Clear of Tool in Nest IO ; : DO[645:GeneralFaults]) ;
29: !PR[115:ToolOffset5] ; 94: ;
30: !X=0 Y=0 Z=-155 Rx=0 Ry=0 Rz=0 ; 95: !Check for Errors ;
31:L PR[106:ToolNest1Pick] 150mm/sec FINE 96: IF DO[645:GeneralFaults]=OFF,JMP LBL[13] ;
Tool_Offset,PR[115:ToolOffset5] 97: ;
: ; 98: !ATI State Check - Seq3 ;
32: ; 99: CALL ATI_CHCK(3) ;
33: !PR[116:ToolOffset6] ; 100: ;
34: !X=0 Y=0 Z=-50 Rx=0 Ry=0 Rz=0 ; 101: JMP LBL[3] ;
35:L PR[106:ToolNest1Pick] 150mm/sec FINE 102: ;
Tool_Offset,PR[116:ToolOffset6] 103: LBL[13:ToolLocked] ;
: ; 104: ;
36: !Reset Out of Nest ; 105: !Set Payload With Tool ;
37: DO[637:OutOfNest]=OFF ; 106: PAYLOAD[1] ;
38: ; 107: ;
39: LBL[10] ; 108: !Verify Tool ID ;
40: ; 109: IF GI[41:ToolIDswtch1Bits]<>R[2:Desired Tool
41: !Check ATI Sensor States ; ID],JMP LBL[6] ;
42: WAIT (!DI[632:ToolLocked] AND 110: ;
!DI[633:ToolUnLocked]) TIMEOUT,LBL[90] ; 111: !Set Frames with new Tool ;
43: ; 111: UTOOL_NUM=5 ;
44: LBL[1:RetryATISeq1] ; 112: UFRAME_NUM=0 ;
45: ; 113: ;
46: !Reset Latch Tool ; 114: !Move Clear of Tool in Nest IO ;
47: DO[632:LatchOrLock]=OFF ; 115:L PR[6:ToolNest1] 50mm/sec FINE ;
48: ; 116: ;
49: !Set Unlatch Tool ; 117: !PR[113:ToolOffset3] ;
50: DO[633:UnlatchOrUnlock]=ON ; 118: !X=0 Y=0 Z=25 Rx=0 Ry=0 Rz=0 ;
51: ; 119:L PR[101:ToolNest1Drop] 50mm/sec FINE
52: WAIT DI[633:ToolUnLocked]=ON TIMEOUT,LBL[633] ; Tool_Offset,PR[113:ToolOffset3]
53: LBL[633] ; : ;
54: ; 120: !ATI State Check - Seq4 ;
55: !Wait for ATI Feedback ; 121: IF DO[645:GeneralFaults]=ON,CALL ATI_CHCK(4) ;
56: WAIT (DI[633:ToolUnLocked] OR 122: ;
DO[645:GeneralFaults]) ; 123: !Set Out of Nest ;
57: ; 124: DO[637:OutOfNest]=ON ;
58: !Check for General Errors ; 125: ;
59: IF DO[645:GeneralFaults]=OFF,JMP LBL[11] ; 126: !PR[112:ToolOffset2] ;
60: ; 127: !X=-5 Y=0 Z=65 Rx=0 Ry=0 Rz=0 ;
61: !ATI State Check - Seq1 ; 128:L PR[101:ToolNest1Drop] 200mm/sec FINE
62: CALL ATI_CHCK(1) ; Tool_Offset,PR[112:ToolOffset2]
63: ; : ;
64: JMP LBL[1] ; 129: !Move Clear Tool Nest ;
65: ; 130: ;
66: LBL[11:ToolUnlocked] ; 131: !PR[111:ToolOffset1] ;
67: ; 132: !X=-150 Y=0 Z=65 Rx=0 Ry=0 Rz=0 ;
68: !Move to Tool Nest ; 133:L PR[101:ToolNest1Drop] 1200mm/sec FINE
69: ; Tool_Offset,PR[111:ToolOffset1]
70: !PR[117:ToolOffset7] ; : ;
AS OF 2/4/2011 108 CUSW REL1.1
134: !Set Frames with new Tool again ; 148: LBL[6:ToolIDMismatch] ;
134: UTOOL_NUM=5 ; 149: ;
135: UFRAME_NUM=0 ; 150: !User Alarm - Unrecognized ;
136: ; 151: !Tool on End-effector ;
137: !Move to Tool Nest Perch ; 152: UALM[1] ;
138:L P[2:Perch Out] 2000mm/sec FINE ; 153: ABORT ;
139: ; 154: ;
140: !Check If Device Is Online ; 155: LBL[90:ATILockUnlockSns] ;
141: CALL DV_STCHK(2,31,3) ; 156: ;
142: IF R[3:Devnet Status]=2,JMP LBL[99] ; 157: !User Alarm - Lock or Unlock ;
143: ; 158: !Sensor Incorrect State ;
144: !Set Device Online ; 159: UALM[26] ;
145: CALL DV_ONLN(2,31,30) ; 160: JMP LBL[10] ;
146: JMP LBL[99] ; 161: ;
147: ; 162: LBL[99:End] ;
AS OF 2/4/2011 109 CUSW REL1.1

Enter Zone 1 (Macro)
1: !****************************** ; 6: DO[33:RobotClrZone1]=OFF ;
2: !Enter Zone 1 Macro ; 7: ;
3: !****************************** ; 8: !Wait for OK To Enter Zone 1 ;
4: ; 9: WAIT DI[33:Zone1ClrToEnter]=ON ;
5: !Reset Clear of Zone 1 ; 10: ;
Home IO (Macro)
1: !****************************** ; 36: DO[58:AtPickup3]=OFF ;
2: !MACRO Setup Outputs ; 37: DO[59:ClrOfDropoff3]=ON ;
3: !****************************** ; 38: DO[60:AtDropoff3]=OFF ;
4: ; 39: DO[61:ClrOfPickup4]=ON ;
5: GO[1:ActiveStyle]=0 ; 40: DO[62:AtPickup4]=OFF ;
7: ; 41: DO[63:ClrOfDropoff4]=ON ;
8: DO[18:RbtAtWork]=OFF ; 42: DO[64:AtDropoff4]=OFF ;
9: DO[19:WorkComplete]=OFF ; 43: ;
10: DO[25:RbtAtPounce]=OFF ; 44: DO[65:Clr2UnclampEarly]=OFF;
11: DO[26:RbtAtService]=OFF ; 45: DO[71:Req2ToEnterTN]=OFF ;
12: DO[28RbtInTipDress]=OFF ; 46: DO[72:ClrOfToolNest]=ON ;
13: DO[29:TipDressComplt]=OFF ; 47: DO[89:PickOverride]=OFF ;
14: DO[31:ClearToTransfer]=ON ; 48: DO[94:AbortPickReq]=OFF ;
15: ; 49: DO[102:StepperRst1Ack]=OFF ;
16: !Zones ; 50: DO[103:StepperRst2Ack]=OFF ;
17: DO[33:RbtClrZone1]=ON ; 51: DO[104:TipBurnInComplt]=OFF ;
18: DO[34:RbtClrZone2]=ON ; 52: DO[105:RbtClrFixt1]=ON ;
21: DO[37:RbtClrZone5]=ON ; 55: GO[2:ReposTooling]=0 ;
22: DO[38:RbtClrZone6]=ON ; 56: ;
23: DO[39:RbtClrZone7]=ON ; 57: GO[31:Disp1StyleBits]=0 ;
24: DO[40:RbtClrZone8]=ON ; 58: DO[393:Disp1RbtinPrc]=OFF ;
25: ; 59: DO[394:Disp1StyStrobe]=OFF ;
26: !Pickup/Dropoff ; 60: DO[401:Disp1Complete]=OFF ;
27: DO[49:ClrOfPickup1]=ON ; 61: ;
28: DO[50:AtPickup1]=OFF ; 62: DO[637:OutOfNest]=ON ;
29: DO[51:ClrOfDropoff1]=ON ; 63: DO[640:ToolNotPresent]=OFF ;
30: DO[52:AtDropoff1]=OFF ; 64: DO[641:InvalidToolReqd]=OFF ;
31: DO[53:ClrOfPickup2]=ON ; 65: DO[642:UnxpctdToolPrsnt]=OFF ;
32: DO[54:AtPickup2]=OFF ; 66: DO[643:Nest not Empty]=OFF ;
33: DO[55:ClrOfDropoff2]=ON ; 67: DO[644:Nest is Empty]=OFF ;
34: DO[56:AtDropoff2]=OFF ; 68: ;
35: DO[57:ClrOfPickup3]=ON ;
AS OF 2/4/2011 110 CUSW REL1.1

Process Application – Ped Spot (Macro)
1: !****************************** ; 41: ;
2: !MACRO PED SPOT WELD; 42: !****************************** ;
3: !****************************** ; 43: LBL[30:TipChange] ;
4: ; 44: ;
5: !Move to Weld 1 ; 45: !MACRO-Tip Dress Ped ;
6: !insert motion if necessary ; 46: CALL TPDRSPD(0) ;
7:L P[1] 1000mm/sec FINE ; 47: ;
8: ; 48: !Reset Tip Dress Complete ;
9: !Select Schedule Weld 1 ; 49: DO[29:TipDressComplt]=OFF ;
10:L P[2] 100mm/sec FINE 50: ;
: SPOT[SD=1,P=1,S=1,ED=1] ; 51: !MACRO-Tip Change Ped ;
11: ; 52: CALL TPCHGPD ;
12: !Move to Weld 2 ; 53: ;
13: !insert motion if necessary ; 54: !MACRO-Tip Dress Ped ;
14:L P[3] 1000mm/sec FINE ; 55: CALL TPDRSPD(58) ;
15: ; 56: ;
16: !Select Schedule Weld 2 ; 57: JMP LBL[20] ;
17:L P[4] 100mm/sec FINE 58: ;
: SPOT[SD=1,P=1,S=1,ED=1] ; 59: !****************************** ;
18: ; 60: LBL[40:TipDress] ;
19: !Move Clear of Ped Welder ; 61: ;
20:L P[5] 1000mm/sec FINE ; 62: !MACRO-Tip Dress Ped ;
21: ; 63: CALL TPDRSPD(62) ;
22: LBL[20] ; 64: ;
23: ; 65: JMP LBL[20] ;
24: !Dropoff/Tip Change/Tip Dress ; 66: ;
25: WAIT (DI[51:GoToDropoff1]=ON OR 67: !****************************** ;
DI[28:TipDressGunReq]=ON OR 68: LBL[50:TipBurnIn] ;
DI[105:TipChangeReq]=ON OR 69: ;
DI[104: TipBurnInReq]=ON OR 70: !MACRO-Tip Burn In ;
DI[27: ServiceRequest]=ON); 71: CALL TPBURNIN ;
26: ; 72: ;
27: !Check for Tip Change ; 73: JMP LBL[20] ;
28: IF DI[105:TipChangeReq]=ON,JMP LBL[30] ; 74: ;
29: ; 75: !****************************** ;
30: !Check for Tip Dress ; 76: LBL[60:Service_W_Part] ;
31: IF DI[28:TipDressGunReq]=ON,JMP LBL[40] ; 77: ;
32: ; 78: !MACRO-Srv_With_Prt ;
33: !Check for Tip Burn In ; 79: CALL Srv_With_Prt ;
34: IF DI[104:TipBurnInReq]=ON,JMP LBL[50] ; 80: ;
35: ; 81: JMP LBL[20] ;
36: !Check for Service Request ; 82: ;
37: IF DI[27:ServiceRequest]=ON,JMP LBL[60] 83: !****************************** ;
38: ; 84: LBL[70:Dropoff] ;
39: !Check for go to Dropoff ; 85: ;
40: IF DI[51:GoToDropoff1]=ON,JMP LBL[70] ;
AS OF 2/4/2011 111 CUSW REL1.1

Process Application – Ped Dispense (Macro) Need Fine
1: !****************************** ; 42: !Move To Seal End, Turn Off Gun ; term type or
2: !MACRO PED DISPENSE ; 43:L P[3] 1000mm/sec CNT100 SE ; more robot
3: !****************************** ; 44: ; positions
4: ; 45: !Move Clear of Nozzle ; (delay time).
5: !Pre-processing for Disp Equip ; 46:L P[4] 1000mm/sec FINE ;
6: !Insert Statements ; 47: ; Because the
7: ; 48: !Reset Coll Guard Sensitivity ; SE instruction
8: !Wait for Dispenser Ready ; 49: COL GUARD ADJUST ; is to close to
9: WAIT (DI[385:Dsp1DispenRdy]=ON) ; 50: ;
10: ; 51: !Set Dispense Complete ;
the
11: !Set Disp Robot in Process ; 52: DO[401:Disp1Complete]=ON ; DO[401:dispe
12: DO[393:Disp1RbtinPrc]=ON ; 53: ; nsecomplete].
13: ; 54: !Wait for Dispense Vol. OK ; The Nordson
14: WAIT .10(sec) ; 55: WAIT DI[387:Dsp1VolumeOK]=ON ;
15: ; 56: ;
may see both
16: !Set Dispense Style ; 57: !Reset Dispense Complete ; signals turn
17: GO[31:Disp1StyBits]=1 ; 58: DO[401:Disp1Complete]=OFF ; ON at the
18: ; Example: SS[1] 59: ; same time due
19: WAIT .10(sec) ; 60: !Reset Disp Robot in Process ;
20: ; –seal schedule is 61: DO[393:Disp1RbtinPrc]=OFF ; to their scan
21: !Set Disp Style Strobe ; using BW TCPP 62: ; rate.
22: DO[394:Disp1StyStrobe]=ON ; (robot tool center 63: !Post-processing for Disp Equip ;
23: ; 64: !Insert Statements ;
24: !Wait for Disp in Process ;
point position) 65: ;
25: WAIT DI[386:Dsp1DispenInPrc]=ON changes
; digital 66: LBL[20] ;
26: ; IO per robot 67: ;
27: !Reset Dispense Style ; speed. In the SS 68: !Purge or Go To Dropoff ;
28: GO[31:Disp1StyBits]=0 ; 69: WAIT (DI[51:GoToDropoff1]=ON OR
29: ;
command use DI[95:PurgeGun1Req]=ON) ;
30: !Reset Disp Style Strobe ; the following per 70: ;
31: DO[394:Disp1StyStrobe]=OFF ; robot speed 71: !Check for Dropoff ;
32: ; 500mm/sec: 72: IF DI[51:GoToDropoff1]=ON,JMP LBL[30] ;
33: !Set Coll Guard Sensitivity ; 73: ;
34: COL GUARD ADJUST R[42] ; 200mm=10volt 74: !MACRO - Purge Ped Gun 1 ;
35: ; 100mm=5volts 75: CALL PRGPDGN1 ;
36: !Move Seal Start, Turn On Gun ; OR 76: ;
37:L P[1] 1000mm/sec CNT100 SS[1] ; Change SS[1] - 77: JMP LBL[20] ;
38: ; 78: ;
39: !Move along Path ; flow rate to be 79: LBL[30:Dropoff] ;
40:L P[2] 100mm/sec CNT100 ; direct voltage 80: ;
41: ;
AS OF 2/4/2011 112 CUSW REL1.1

Process Application – Ped Stud (Macro)
1: !****************************** ; 12: !Move to Weld 2 ;
2: !MACRO PED STUD WELD; 13: !insert motion if necessary ;
3: !****************************** ; 14:L P[3] 1000mm/sec FINE ;
4: ; 15: ;
5: !Move to Weld 1 ; 16: !Select Schedule Weld 2 ;
6: !insert motion if necessary ; 17:L P[4] 100mm/sec FINE
7:L P[1] 1000mm/sec FINE ; : SPOT[S=1] ;
8: ; 18: ;
9: !Select Schedule Weld 1 ; 19: !Move Clear of Ped Welder ;
10:L P[2] 100mm/sec FINE 20:L P[5] 1000mm/sec FINE ;
: SPOT[S=1] ; 21: ;
11: ;
Purge Ped Gun (Macro)

1: !****************************** ; 14: !Wait 'X' Seconds ;
2: !MACRO PURGE PED GUN 1 ; 15: WAIT 7.00(sec) ;
3: !****************************** ; 16: ;
4: ; 17: !Turn Off Gun ;
5: !Set Ext Purge 1 in Progress ; 18: DO[416:Disp1Purge]=OFF ;
6: DO[97:ExtPurg1InProgrs]=ON ; 19: ;
7: ; 20: !Post-process Disp Equipment ;
8: !Pre-process Dispense Equipment ; 21: !(insert statements) ;
9: !(insert statements) ; 22: ;
10: ; 23: !Reset Ext Purge 1 in Progress ;
11: !Turn On Gun-Purge Schedule ; 24: DO[97:ExtPurg1InProgrs]=OFF ;
12: DO[416:Disp1Purge]=ON ; 25: ;
13: ;

1: !****************************** ; 8: !Wait for Stepper Reset ;
2: !MACRO RESET STEPPER ; 9: WAIT DI[204:W1 SteppersReset]=ON ;
3: !****************************** ; 10: ;
4: ; 11: !Reset Weld 1 Reset Stepper ;
5: !Set Weld 1 Reset Stepper ; 12: DO[590:W1ResetStepper]=OFF ;
6: DO[590:W1ResetStepper]=ON ; 13: ;
7: ;
Tip Burn In (Macro)

1: !****************************** ; 13: !Total Number of Burn Ins ;
2: !MACRO TIP BURN IN ; 14: R[14]=R[14]+1 ;
3: !****************************** ; 15: ;
4: ; 16: !Check Number of Burn-ins ;
5: !Reset Registers for Burn In ; 17: IF R[14]<R[15],JMP LBL[1] ;
6: R[14]=0 ; 18: ;
7: ; 19: !MACRO-Tip Wear Compensation ;
8: LBL[1] ; 20: CALL WR_UPDAT(1,0) ;
9: ; 21: ;
10: !Burn In ; 22: !Set Tip Burn-in Complete ;
11:L P[1] 100mm/sec FINE 23: DO[104:TipBurnInComplt]=ON ;
: SPOT[SD=1,P=1,S=62,ED=1] ; 24: ;
12: ;
Tip Change Ped Gun (Macro)

1: !****************************** ; 16: ;
2: !MACRO TIP CHANGE PED GUN ; 17: !Reset Robot at Service ;
3: !****************************** ; 18: DO[26:RbtAtService]=OFF ;
4: ; 19: ;
5: !Pulse W1 Water Off ; 20: !Reset Ready for Tip Change ;
6: DO[587:W1WtrOff]=PULSE,1.0sec ; 21: DO[30:RdyForTipChg]=OFF ;
7: ; 22: ;
8: !Set Robot at Service ; 23: !MACRO-Reset Stepper ;
9: DO[26:RbtAtService]=ON ; 24: CALL RST_STPR ;
10: ; 25: ;
11: !Set Ready for Tip Change ; 26: !MACRO-Seat Caps Gun 1 ;
12: DO[30:RdyForTipChg]=ON ; 27: CALL TW_PRSRT(1,500,2,4,1,10,5,15) ;
13: ; 28: ;
14: !Wait for Service Complete ; 29: !Tip Wear Compensation Gun 1 ;
15: WAIT (DI[26:ServiceCompltReq]=ON) ; 30: CALL WR_UPDAT(1,0) ;
AS OF 2/4/2011 113 CUSW REL1.1

31: ; 33: DO[586:W1RstWtrSvr]=PULSE,1.0sec ;
32: !Pulse W1 Reset Water Saver ; 34: ;
AS OF 2/4/2011 114 CUSW REL1.1

1: !****************************** ; 28: ;
2: !MACRO TIP DRESS CARRIED GUN 1 ; 29: !Move Away Tip Dresser ;
3: !****************************** ; 30:L P[4] 500mm/sec FINE ;
5: !1: Burn In Schedule Gun 1 ; 32: !Reset Turn On Tip Dresser ;
6: !****************************** ; 33: DO[101:TurnOnTipDresser]=OFF ;
7: ; 34: ;
8: !Setup Weld Register ; 35: !Check If Burn In Required ;
9: R[19:Gun1BurnInSched]=AR[1] ; 36: IF R[19:Gun1BurnInSched]=0,JMP LBL[10] ;
10: ; 37: ;
11: !Set Robot In Tip Dress ; 38: !Do Tip Burn In Weld Schedule ;
12: DO[28:RbtInTipDress]=ON ; 39:L P[5] 100mm/sec FINE
13: ; : SPOT[SD=1,P=1,S=R[19],ED=1] ;
14: !Move Common Dress Approach ; 40: ;
15:L P[1] 500mm/sec FINE ; 41: !MACRO-Tip Wear Compensation ;
16: ; 42: CALL WR_UPDAT(1,0) ;
17: !Turn On Tip Dresser ; 43: ;
18: DO[101:TurnOnTipDresser]=ON ; 44: LBL[10:SkipBurnIn] ;
19: ; 45: ;
20: !Wait Tip Dress Motor On ; 46: !Reset Tip Dress Request ;
21: WAIT DI[101:TipDrsMotorOn]=ON ; 47: DO[100:TipDressReq1]=OFF ;
22: ; 48: ;
23: !Move To Tip Dresser ; 49: !Set Tip Dress Complete ;
24:L P[2] 500mm/sec FINE ; 50: DO[29:TipDressComplt]=ON ;
25: ; 51: ;
26: !Do Tip Dress Weld Schedule ; 52: !Reset Robot in Tip Dress ;
27:L P[3] 100mm/sec FINE 53: DO[28:RbtInTipDress]=OFF ;
: SPOT[SD=1,P=1,S=60,ED=1] ; 54: ;

1: !****************************** ; 28: ;
2: !MACRO TIP DRESS CARRIED GUN 2 ; 29: !Move Away Tip Dresser ;
3: !****************************** ; 30:L P[4] 500mm/sec FINE ;
5: !1: Burn In Schedule Gun 2; 32: !Reset Turn On Tip Dresser ;
7: ; 34: ;
8: !Setup Weld Register ; 35: !Check If Burn In Required ;
9: R[20:Gun2BurnInSched]=AR[1] ; 36: IF R[20:Gun2BurnInSched]=0,JMP LBL[10] ;
10: ; 37: ;
11: !Set Robot in Tip Dress ; 38: !Do Tip Burn In Weld Schedule ;
12: DO[28:RbtInTipDress]=ON ; 39:L P[5] 100mm/sec FINE
13: ; : SPOT[SD=1,P=1,S=R[20],ED=1] ;
14: !Move Common Dress Approach ; 40: ;
15:L P[1] 500mm/sec FINE ; 41: !MACRO-Tip Wear Compensation ;
16: ; 42: CALL WR_UPDAT(2,0) ;
17: !Turn On Tip Dresser ; 43: ;
18: DO[101:TurnOnTipDresser]=ON ; 44: LBL[10:SkipBurnIn] ;
19: ; 45: ;
20: !Wait Tip Dress Motor On ; 46: !Reset Tip Dress Request ;
21: WAIT DI[101:TipDrsMotorOn]=ON ; 47: DO[48:TipDressReq2]=OFF ;
22: ; 48: ;
23: !Move To Tip Dresser ; 49: !Set Tip Dress Complete ;
24:L P[2] 500mm/sec FINE ; 50: DO[29:TipDressComplt]=ON ;
25: ; 51: ;
26: !Do Tip Dress Weld Schedule ; 52: !Reset Robot in Tip Dress ;
27:L P[3] 100mm/sec FINE 53: DO[28:RbtInTipDress]=OFF ;
: SPOT[SD=1,P=1,S=61,ED=1] ; 54: ;
AS OF 2/4/2011 115 CUSW REL1.1

Tip Dress Ped Gun (Macro)
2: !MACRO TIP DRESS PED GUN ; 28: ;
3: !****************************** ; 29: !Reset Tip Dress Request ;
4: !Parameters: AR[] ; 30: DO[100:TipDressReq1]=OFF ;
5: !1: Burn In Schedule Gun 1 ; 31: ;
6: !****************************** ; 32: !Set Tip Dress Complete ;
7: ; 33: DO[29:TipDressComplt]=ON ;
8: !Setup Weld Register ; 34: ;
9: R[19:Gun1BurnInSched]=AR[1] ; 35: !Wait for Tip Dress Dump Ret ;
10: ; 36: WAIT DI[100:TipDrsDumpRtrct]=ON ;
11: !Set Robot in Tip Dress ; 37: ;
12: DO[28:RbtInTipDress]=ON ; 38: !Check If Burn In Required ;
13: ; 39: IF R[19:Gun1BurnInSched]=0,JMP LBL[10] ;
14: !Wait for Tip Dress Dump Ext ; 40: ;
15: WAIT DI[99:TipDressDumpExtd]=ON ; 41: !Do Tip Burn In Weld Schedule ;
16: ; 42:L P[2] 100mm/sec FINE
17: !Turn On Tip Dresser ; : SPOT[SD=1,P=1,S=R[19],ED=1] ;
18: DO[101:TurnOnTipDresser]=ON ; 43: ;
19: ; 44: !MACRO-Tip Wear Compensation ;
20: !Wait Tip Dress Motor On ; 45: CALL WR_UPDAT(1,0) ;
21: WAIT DI[101:TipDrsMotorOn]=ON ; 46: ;
22: ; 47: LBL[10:SkipBurnIn] ;
23: !Do Tip Dress Weld Schedule ; 48: ;
24:L P[1] 100mm/sec FINE 49: !Reset Robot in Tip Dress ;
: SPOT[SD=1,P=1,S=60,ED=1] ; 50: DO[28:RbtInTipDress]=OFF ;
25: ; 51: ;
26: !Reset Turn On Tip Dresser ;
AS OF 2/4/2011 116 CUSW REL1.1

Tool Drop Preperation (Macro)
1: !****************************** ; 64: ;
2: !MACRO TOOL DROP PREPARATION ; 65: !Verify Nest Empty Before Drop ;
3: !****************************** ; 66: IF DI[75:ToolInNest3]=ON,JMP LBL[95] ;
4: ; 67: ;
5: LBL[1:Retry] ; 68: !MACRO-Drop Tool in Nest 3 ;
6: ; 69: CALL NST3DROP ;
7: !Select Tool ; 70: ;
8: SELECT R[1]=1,JMP LBL[10] ; 71: JMP LBL[99] ;
9: =2,JMP LBL[20] ; 72: ;
10: =3,JMP LBL[30] ; 73: ;
11: =4,JMP LBL[40] ; 74: LBL[40:Tool4] ;
12: ELSE,JMP LBL[90] ; 75: ;
13: ; 76: !Verify Part Not Present ;
14: LBL[10:Tool1] ; 77: Check No Part(1,2,3,4) ;
15: ; 78: ;
16: !Verify Part Not Present ; 79: !MACRO-Set Active MH Tool ;
17: Check No Part(1,2,3,4) ; 80: Set MH Tool(4) ;
18: ; 81: ;
19: !MACRO-Set Active MH Tool ; 82: !Set Tool 4 Drop State ;
20: Set MH Tool(1) ; 83: Release Part(1) ;
21: ; 84: ;
22: !Set Tool 1 Drop State ; 85: !Verify Nest Empty Before Drop ;
23: Release Part(1) ; 86: IF DI[76:ToolInNest4]=ON,JMP LBL[95] ;
24: ; 87: ;
25: !Verify Nest Empty Before Drop ; 88: !MACRO-Drop Tool in Nest 4 ;
26: IF DI[73:ToolInNest1]=ON,JMP LBL[95] ; 89: CALL NST4DROP ;
27: ; 90: ;
28: !MACRO-Drop Tool in Nest 1 ; 91: JMP LBL[99] ;
29: CALL NST1DROP ; 92: ;
30: ; 93: !****************************** ;
31: JMP LBL[99] ; 94: !ALARMS ;
32: ; 95: !****************************** ;
33: ; 96: ;
34: LBL[20:Tool2] ; 97: !Unexpected Tool Present ;
35: ; 98: LBL[90:WrongTool] ;
36: !Verify Part Not Present ; 99: ;
37: Check No Part(1,2,3,4) ; 100: !Set Application Error Output ;
38: ; 101: DO[642:UnxpctdToolPrsnt]=ON ;
39: !MACRO-Set Active MH Tool ; 102: ;
40: Set MH Tool(2) ; 103: !Post User Alarm ;
41: ; 104: UALM[3] ;
42: !Set Tool 2 Drop State ; 105: ;
43: Release Part(1) ; 106: !Reset Appliction Error Output ;
44: ; 107: DO[642:UnxpctdToolPrsnt]=OFF ;
45: !Verify Nest Empty Before Drop ; 108: ;
46: IF DI[74:ToolInNest2]=ON,JMP LBL[95] ; 109: JMP LBL[1] ;
47: ; 110: ;
48: !MACRO-Drop Tool in Nest 2 ; 111: !Nest not Empty;
49: CALL NST2DROP ; 112: LBL[95:Nest not Empty] ;
50: ; 113: ;
51: JMP LBL[99] ; 114: !Set Application Error Output ;
52: ; 115: DO[643:Nest not Empty]=ON ;
53: ; 116: ;
54: LBL[30:Tool3] ; 117: !Post User Alarm ;
55: ; 118: UALM[4] ;
56: !Verify Part Not Present ; 119: ;
57: Check No Part(1,2,3,4) ; 120: !Reset Not not Empty ;
58: ; 121: DO[643:Nest not Empty]=OFF ;
59: !MACRO-Set Active MH Tool ; 122: ;
60: Set MH Tool(3) ; 123: JMP LBL[1] ;
61: ; 124: ;
62: !Set Tool 3 Drop State ; 125: LBL[99:End] ;
63: Release Part(1) ; 126: ;
AS OF 2/4/2011 117 CUSW REL1.1

Tool Pick Preperation (Macro)
1: !****************************** ; 45: ;
2: !MACRO TOOL PICK PREPARATION ; 46: !Verify Tool in Nest B4 Pick ;
3: !****************************** ; 47: IF DI[76:ToolInNest4]=OFF,JMP LBL[95] ;
4: ; 48: ;
5: LBL[1] ; 49: !MACRO-Pick Tool in Nest 4 ;
6: ; 50: CALL NST4PICK ;
7: !Select Tool Nest for Pick ; 51: ;
8: SELECT R[2]=1,JMP LBL[10] ; 52: JMP LBL[99] ;
9: =2,JMP LBL[20] ; 53: ;
10: =3,JMP LBL[30] ; 54: !****************************** ;
11: =4,JMP LBL[40] ; 55: !ALARMS ;
12: ELSE,JMP LBL[90] ; 56: !****************************** ;
13: ; 57: ;
14: LBL[10:Tool1] ; 58: !Invalid Tool Requested ;
15: ; 59: LBL[90:WrongTool] ;
16: !Verify Tool in Nest B4 Pick ; 60: ;
17: IF DI[73:ToolInNest1]=OFF,JMP LBL[95] ; 61: !Set Application Error ;
18: ; 62: !DO[641:InvalidToolReqd]=ON ;
19: !MACRO-Pick Tool in Nest 1 ; 63: ;
20: CALL NST1PICK ; 64: !Post User Alarm ;
21: ; 65: UALM[2] ;
22: JMP LBL[99] ; 66: ;
23: ; 67: !Reset Application Error ;
24: LBL[20:Tool2] ; 68: !DO[641:InvalidToolReqd]=OFF ;
25: ; 69: ;
26: !Verify Tool in Nest B4 Pick ; 70: JMP LBL[1] ;
27: IF DI[74:ToolInNest2]=OFF,JMP LBL[95] ; 71: ;
28: ; 72: !Tool Nest is Empty ;
29: !MACRO-Pick Tool in Nest 2 ; 73: LBL[95:Nest is Empty] ;
30: CALL NST2PICK ; 74: ;
31: ; 75: !Set Application Error ;
32: JMP LBL[99] ; 76: DO[644:Nest is Empty]=ON ;
33: ; 77: ;
34: LBL[30:Tool3] ; 78: !Post User Alarm ;
35: ; 79: UALM[5] ;
36: !Verify Tool in Nest B4 Pick ; 80: ;
37: IF DI[75:ToolInNest3]=OFF,JMP LBL[95] ; 81: !Reset Application Error ;
38: ; 82: DO[644:Nest is Empty]=OFF ;
39: !MACRO-Pick Tool in Nest 3 ; 83: ;
40: CALL NST3PICK ; 84: JMP LBL[1] ;
41: ; 85: ;
42: JMP LBL[99] ; 86: LBL[99:End] ;
43: ; 87: ;
44: LBL[40:Tool4] ;
AS OF 2/4/2011 118 CUSW REL1.1


CHRYSLER CUSW FANUC Robot Standard Rev1 1

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CHRYSLER CUSW FANUC Robot Standard Rev1 1

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Chrysler’s

Robotics Group Applications Standards For

Controlled Robots For Use On

AS OF 2/4/2011 1 CUSW REL1.1

PROCESS REQUIREMENTS TO ALLOW FOR ALIGNMENT OF ROBOT ............................................................ 6

ROBOTIC BY-PASS CONCEPT ............................................................................................................................... 6

TEACH PENDANT USER KEY ASSIGNMENT ........................................................................................................ 6

USE OF PULSED OUTPUTS .................................................................................................................................... 6

USE OF ROBOT PROGRAM SPACE CHECK ........................................................................................................ 6

COORDINATED MOTION OF HORIZONTAL AXIS ................................................................................................. 6

ROBOT DRESS REQUIREMENTS........................................................................................................................... 6

FANUC ROBOTICS ROBOT SIGNALS AND MACHINE AUTOMATIC .................................................................. 7

ROBOT D-NET OUTPUT BIT MAP (ROBOT TO PLC)............................................................................................ 8

ROBOT D-NET INPUT BIT MAP (PLC TO ROBOT).............................................................................................. 12

ROBOT IO MAP ASSIGNMENTS ........................................................................................................................... 16

ROBOT BIT MAP .................................................................................................................................................... 17

ROBOT APPLICATION ERROR TIMING ............................................................................................................... 36

ROBOT APPLICATION ERRORS .......................................................................................................................... 37

PLC LOGIC REFERENCE ...................................................................................................................................... 43

ROBOT PROGRAM NAMING ................................................................................................................................. 44

ROBOT INTERFERENCE ZONES.......................................................................................................................... 45

REGISTER USAGE ................................................................................................................................................. 51

NUMERICAL REGISTER USAGE .......................................................................................................................... 51

POSITION REGISTER USAGE ............................................................................................................................... 53

USER ALARMS ....................................................................................................................................................... 55

REFERENCE POSITION USAGE ........................................................................................................................... 56

FLOW CHART EXAMPLES .................................................................................................................................... 60

AS OF 2/4/2011 2 CUSW REL1.1

AS OF 2/4/2011 3 CUSW REL1.1

AS OF 2/4/2011 4 CUSW REL1.1

PROCESS CYCLE TIME REQUIREMENTS

ROBOTIC BY-PASS CONCEPT

TEACH PENDANT USER KEY ASSIGNMENT

USE OF PULSED OUTPUTS

USE OF ROBOT PROGRAM SPACE CHECK

COORDINATED MOTION OF HORIZONTAL AXIS

ROBOT DRESS REQUIREMENTS

AS OF 2/4/2011 6 CUSW REL1.1

CMDENBL SI[2]=ON (OK) (standard operator panel input 2, remote)

Robot System Ready for AUTO

AS OF 2/4/2011 7 CUSW REL1.1

AS OF 2/4/2011 8 CUSW REL1.1

AS OF 2/4/2011 10 CUSW REL1.1

AS OF 2/4/2011 11 CUSW REL1.1

AS OF 2/4/2011 12 CUSW REL1.1

AS OF 2/4/2011 13 CUSW REL1.1

AS OF 2/4/2011 14 CUSW REL1.1

ROBOT OUTPUTS ROBOT INPUTS

AS OF 2/4/2011 15 CUSW REL1.1

SPARES DO [129 - 192] DI [129 - 192]

SPOT WELD SCR#1 DO [193 - 224] DI [193 - 224] 11

NELSON STUD WELDER DO [321 - 384] DI [321 - 384] 16

DISPENSE #1 DO [385 - 448] DI [385 - 448] 25

MH EOAT MODULE #1 INPUT DI [513 - 528] 31

MH EOAT MODULE #1 OUTPUT DO [513 - 544] 39

SPARE DO [577 - 585]

MH EOAT VAC MODULE #1 DO [593 - 600] DI [593 - 600] 37

SPARE DO [625 - 631] DI [625 - 631]

ATI TOOLCHANGER DO [632 - 639] DI [632 - 695] 54

SPARES DO [640 - 695]

FORM & PIERCE MOOG DO [696 - 727] DI [696 - 727] 48

SPARES DO [768 - 784] DI [768 - 784]

SPARES DO [785 - 792] DI [785 - 816] 17

SPARES DO [793 - 816]